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† Accessory drive belt (Refer to 7 - COOLING/AC- CESSORY DRIVE/DRIVE BELTS - INSTALLATION) † Radiator fan (Refer to 7 - COOLING/ENGINE/
RADIATOR FAN - INSTALLATION)
(4) Connect the negative cable to the battery.
Fig.46InstallingCrankshaftPulley—Damper
1 - SPECIAL TOOL C-3688
FRONT MOUNT REMOVAL
(1) Disconnect the negative cable from the battery. (2) Position fan to assure clearance for radiator top
tank and hose.
CAUTION: DO NOT lift the engine by the intake manifold.
(3) Install engine support/lifting fixture. (4) Raise vehicle on hoist. (5) Lift the engine SLIGHTLY and remove the
thru-bolt and nut.
Remove shields.
(6) Remove engine support bracket/cushion bolts. support bracket/cushion and heat
the
INSTALLATION
(1) With engine raised SLIGHTLY, position the engine support bracket/cushion and heat shields to the block. Install new bolts and tighten to 81 N·m (60
ft. lbs.) torque.(2) Install the thru-bolt and 2 piece rubber engine rubber restrictors onto the engine support bracket/ cushion.
DR FRONT MOUNT (Continued)
ENGINE 8.0L
9 - 393
(3) Lower engine with support/lifting fixture while guiding the engine bracket/cushion and thru-bolt into support cushion brackets.
(4) Install thru-bolt nuts and tighten the nuts to
68 N·m (50 ft. lbs.) torque.
(5) Lower the vehicle. (6) Remove lifting fixture.
REAR MOUNT REMOVAL
(1) Raise the vehicle on a hoist. (2) Position a transmission jack in place. (3) Remove support cushion stud nuts (Fig. 47). (4) Raise SLIGHTLY.
transmission
rear
and
of
engine
(5) Remove the bolts holding the support cushion to the transmission support bracket. Remove the sup- port cushion.
(6) If necessary, remove the bolts holding the
transmission support bracket to the transmission.
INSTALLATION
(1) If removed, position the transmission support bracket to the transmission. Install new attaching bolts and tighten to 102 N·m (75 ft. lbs.) torque.
(2) Position support cushion to transmission sup- port bracket. Install stud nuts and tighten to 47 N·m (35 ft. lbs.) torque.
(3) Using the transmission jack, lower the trans- mission and support cushion onto the crossmember (Fig. 110).
(4) Install the support cushion bolts and tighten to
47 N·m (35 ft. lbs.) torque.
(5) Remove the transmission jack. (6) Lower the vehicle.
LUBRICATION DESCRIPTION
A pressure feed type (gerotor) oil pump is located in the engine front cover. The pump uses a pick-up tube and screen assembly to gather engine oil from the oil pan (Fig. 48).
OPERATION
The pump draws oil through the screen and inlet tube from the sump at the rear of the oil pan. The oil is driven between the inner and outer gears of the oil pump, then forced through the outlet in the engine front cover. An oil gallery in the front cover channels the oil to the inlet side of the full flow oil filter. After passing through the filter element, the oil passes
Fig.47EngineRearSupportCushionAsse
ENGINE 8.0L
9 - 394
LUBRICATION (Continued)DR
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING—ENGINE OIL LEAKS
Begin with a through visual
inspection of the engine, particularly at the area of the suspected leak. If an oil leak source is not readily identifiable, the following steps should be followed:
(1) Do not clean or degrease the engine at this time because some solvents may cause rubber to swell, temporarily stopping the leak.
(2) Add an oil-soluble dye (use as recommended by manufacturer). Start the engine and let idle for approximately 15 minutes. Check the oil dipstick to be sure the dye is thoroughly mixed as indicated with a bright yellow color under a black light source. (3) Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area of oil leak. If the oil leak is found and identified, repair per service manual instructions.
(4) If dye is not observed, drive the vehicle at var- ious speeds for approximately 24km (15 miles), and repeat previous step.
(5) If the oil leak source is not positively identified at this time, proceed with the air leak detection test method as follows:
(6) Disconnect the breather cap to air cleaner hose at the breather cap end. Cap or plug breather cap nipple.
(7) Remove the PCV valve from the cylinder head
cover. Cap or plug the PCV valve grommet.
(8) Attach an air hose with pressure gauge and
regulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to more than 20.6 kpa (3 PSI) of test pressure.
(9) Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus- pected source. Adjust the regulator to the suitable test pressure that provide the best bubbles which will pinpoint the leak source. If the oil leak is detected and identified, repair per service manual procedures.(10) If the leakage occurs at the rear oil seal area, refer to the section, Inspection for Rear Seal Area Leak.
(11) If no leaks are detected, turn off the air sup- ply and remove the air hose and all plugs and caps. Install the PCV valve and breather cap hose. Proceed to next step.
(12) Clean the oil off the suspect oil
leak area using a suitable solvent. Drive the vehicle at various speeds approximately 24 km (15 miles). Inspect the engine for signs of an oil leak by using a black light.
Fig.48PressureFeedType(Gerotor)OilPump—
Typical
1 - OUTER ROTOR 2 - INNER ROTOR 3 - OIL PUMP COVER 4 - TIMING CHAIN COVER
from the center outlet of the filter through an oil gal- lery that channels the oil up to the tappet galleries, which extends the entire length of block.
Galleries extend downward from the main oil gal- lery to the upper shell of each main bearing. The crankshaft is drilled internally to pass oil from the main bearing journals to the connecting rod journals. Each connecting rod bearing has half a hole in it, oil passes through the hole when the rods rotate and the is then thrown off as the rod hole lines up, oil rotates. This oil throwoff lubricates the camshaft lobes, cylinder walls, and piston pins.
The hydraulic valve tappets receive oil directly from the main oil gallery. The camshaft bearings receive oil from the main bearing galleries. The front camshaft bearing journal passes oil through the cam- shaft sprocket to the timing chain. Oil drains back to the oil pan under the No. 1 main bearing cap.
The oil supply for the rocker arms and bridged pivot assemblies is provided by the hydraulic valve tappets, which pass oil through hollow push rods to a hole in the corresponding rocker arm. Oil from the rocker arm lubricates the valve train components. The oil then passes down through the push rod guide holes and the oil drain-back passages in the cylinder head, past the valve tappet area, and then returns to the oil pan (Fig. 49).
DR LUBRICATION (Continued)
ENGINE 8.0L
9 - 395
Fig.49EngineLubricationSystem
ENGINE 8.0L
9 - 396
LUBRICATION (Continued)1 - OIL TO MAIN OIL GALLERIES 2 - RELIEF VALVE 3 - OIL GALLERY FOR TAPPETS 4 - MAIN OIL GALLERY 5 - TAPPET OIL GALLERY 6 - HOLLOW PUSH ROD 7 - ROCKER ARM 8 - PLUG 9 - GASKET 10 - SPRING 11 - TIMING CHAIN COVER 12 - CAM BEARINGS 13 - HYDRAULIC TAPPET GALLERIES 14 - CAMSHAFT 15 - CRANKSHAFT
DR
16 - OIL PASSAGE TO CONNECTING ROD JOURNALS 17 - OIL PICKUP 18 - CONNECTING ROD JOURNALS 19 - CRANKSHAFT BEARINGS 20 - MAIN OIL GALLERY 21 - CRANKSHAFT 22 - OIL PICKUP TUBE 23 - CONNECT ROD JOURNALS 24 - CAMSHAFT BEARINGS 25 - TAPPET OIL GALLERY 26 - OIL FROM PICKUP TUBE 27 - CAMSHAFT 28 - TAPPET 29 - VALVE 30 - OIL PUMP RELIEF VALVE
DIAGNOSIS AND TESTING—ENGINE OIL PRESSURE
(1) Remove oil pressure sending unit. (2) Install Oil Pressure Line and Gauge Tool C-3292. Start engine and record pressure. (Refer to 9
- ENGINE - SPECIFICATIONS).OIL STANDARD PROCEDURE - ENGINE OIL
OIL LEVEL INDICATOR (DIPSTICK)
The engine oil level indicator is located at the right
front of the engine, left of the generator (Fig. 50).
Fig.50OilLevelIndicatorLocation
1 - CYLINDER HEAD COVER 2 - ENGINE OIL FILL CAP 3 - DIPSTICK 4 - ENGINE OIL FILTER 5 - FILTER BOSS
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil, oil foaming and oil pressure loss can result.
To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick.
(1) Position vehicle on level surface. (2) With engine OFF, allow approximately ten min- utes for oil to settle to bottom of crankcase, remove engine oil dipstick.
(3) Wipe dipstick clean. (4) Install dipstick and verify it is seated in the tube. (5) Remove dipstick, with handle held above the
tip, take oil level reading.
(6) Add oil only if level is below the ADD mark on
dipstick.
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals described in the Maintenance Schedule. This infor- mation can be found in the owner’s manual.
TO CHANGE ENGINE OIL
Run engine until achieving normal operating tem-
perature.
engine off.
(1) Position the vehicle on a level surface and turn
(2) Hoist vehicle. (3) Remove oil fill cap. (4) Place a suitable drain pan under crankcase drain. (5) Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged.
(6) Install drain plug in crankcase. (7) Change oil filter (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - REMOVAL).
(8) Lower vehicle and fill crankcase with specified type (Refer to LUBRICATION & MAINTENANCE/ FLUID TYPES - DESCRIPTION) and amount of engine oil (Refer to LUBRICATION & MAINTE- NANCE - SPECIFICATIONS).
(9) Install oil fill cap. (10) Start engine and inspect for leaks. (11) Stop engine and inspect oil level.
DR
OIL FILTER REMOVAL
ENGINE 8.0L
9 - 397
All engines are equipped with a high quality full- flow, disposable type oil filter. DaimlerChrysler Cor- poration recommends a Mopart or equivalent oil filter be used.
(1) Position a drain pan under the oil filter. (2) Using a suitable oil filter wrench loosen filter. (3) Rotate the oil filter counterclockwise to remove
it from the cylinder block oil filter boss (Fig. 51).
Fig.52OilFilterSealingSurface—Typical
1 - SEALING SURFACE 2 - RUBBER GASKET 3 - OIL FILTER
(6) Remove the oil pick-up tube assembly (Fig. 53).
Discard the gasket.
Fig.51OilFilterRemoval—Typical
1 - ENGINE OIL FILTER 2 - OIL FILTER WRENCH
(4) When filter separates from adapter nipple, tip gasket end upward to minimize oil spill. Remove fil- ter from vehicle.
(5) With a wiping cloth, clean the gasket sealing
surface (Fig. 52) of oil and grime.
(6) Install new filter (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - INSTALLATION).
INSTALLATION
Fig.53OilPick-UpTube
(1) Lightly lubricate oil filter gasket with engine
oil or chassis grease.
(2) Thread filter onto adapter nipple. When gasket makes contact with sealing surface, (Fig. 52) hand tighten filter one full turn, do not over tighten.
(3) Add oil (Refer to 9 - ENGINE/LUBRICATION/
OIL - STANDARD PROCEDURE).
OIL PAN REMOVAL
(1) Disconnect the negative cable from the battery. (2) Raise vehicle. (3) Drain engine oil. (4) Remove left engine to transmission strut. (5) Remove oil pan mounting bolts, pan and one- piece gasket. The engine may have to be raised slightly on 2WD vehicles.
1 - PICK—UP TUBE 2 - SEALANT AT SPLIT-LINES 3 - SEALANT AT SPLIT-LINE
CLEANING
Clean the block and pan gasket surfaces. If present, trim excess sealant from inside the
Clean oil pan in solvent and wipe dry with a clean
engine.
cloth.
Clean oil screen and pipe thoroughly in clean sol-
vent. Inspect condition of screen.
INSPECTION
Inspect oil drain plug and plug hole for stripped or
damaged threads. Repair as necessary.
Inspect oil pan mounting flange for bends or distor-
tion. Straighten flange, if necessary.
9 - 398
ENGINE 8.0L OIL PAN (Continued) INSTALLATION(1) Fabricate 4 alignment dowels from 5/16 x 1 1/2
inch bolts. Cut the head off the bolts and cut a slot into the top of the dowel. This will allow easier installation and removal with a screwdriver (Fig. 54). (2) Install the dowels in the cylinder block at theFig.54FabricationofAlignmentDowels
1 - 5/16” X 11⁄2” BOLT 2 - DOWEL 3 - SLOT
four corners.
(3) Apply small amount of Mopart Silicone Rubber Adhesive Sealant, or equivalent at the split lines. The split lines are between the cylinder block, the timing chain cover and the rear crankshaft seal assembly (Fig. 53). After the sealant is applied you have 3 minutes to install the gasket and oil pan.
(4) Slide the one-piece gasket over the dowels and
onto the block.
(5) Position the oil pan over the dowels and onto the gasket. The engine may have to be slightly raised on 2WD vehicles.
(6) Install the oil pan bolts (Fig. 55). Tighten the
bolts to as shown in Oil Pan Bolts Torque Chart.
DR
(7) Remove the dowels. Install the remaining 5/16
inch oil pan bolts. Torque these bolts as shown in Oil Pan Bolts Torque Chart.(8) Install the drain plug. Tighten drain plug to 34
N·m (25 ft. lbs.) torque.
(9) Install the engine to transmission strut. (10) Lower vehicle. (11) Connect the negative cable to the battery. (12) Fill crankcase with oil to proper level. (13) Start engine and check for leaks.
OIL PUMP REMOVAL
(1) Remove the timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).
(2) Remove the relief valve plug, gasket, spring
and valve (Fig. 56). Discard the gasket.
Fig.56OilPressureReliefValve
1 - TIMING CHAIN COVER 2 - OIL PUMP RELIEF VALVE 3 - SPRING 4 - GASKET 5 - PLUG
(3) Remove mounting screws and oil pump cover
(4) Remove oil pump inner and outer rotors (Fig.
(Fig. 57).
57).
(5) Inspect oil pump for wear (Refer to 9 - INSPEC-
ENGINE/LUBRICATION/OIL PUMP - TION).
Fig.55OilPanBoltLocation
1 - OIL PAN 2 - OIL FILTER 3 - STUD BOLTS 4 - DRAIN PLUG
CLEANING
Wash all parts in a suitable solvent and inspect
carefully for damage or wear.
DR OIL PUMP (Continued)
ENGINE 8.0L
9 - 399
mm (0.5876 inch) or less, or if the diameter is 82.45
mm (3.246 inches) or less, replace rotor set.Fig.57OilPump
1 - OUTER ROTOR 2 - INNER ROTOR 3 - OIL PUMP COVER 4 - TIMING CHAIN COVER
INSPECTION
Mating surface of the oil pump cover should be smooth. Replace pump cover if scratched or grooved. Lay a straightedge across the pump cover surface (Fig. 58). If a 0.076 mm (0.003 inch) feeler gauge can be inserted between cover and straightedge, cover should be replaced.
Fig.59MeasuringOuterRotorThickness
Fig.60MeasuringInnerRotorThickness
Slide outer rotor into timing chain cover pump body. Press rotor to the side with your fingers and measure clearance between rotor and pump body (Fig. 61). If clearance is 0.19 mm (0.007 inch) or more, and outer rotor is within specifications, replace timing chain cover.
Install inner rotor into timing chain cover pump body (Fig. 62). Inner rotor should be positioned with chamfer up or toward engine when cover is installed. This allows easy installation over crankshaft. If clearance between inner and outer rotors is 0.150
mm (0.006 inch) or more, replace both rotors.Place a straightedge across the face of the timing chain cover pump body, between bolt holes (Fig. 63). If a feeler gauge of 0.077 mm (0.003 inch) or more can be inserted between rotors and the straightedge, and the rotors are within specifications, replace tim- ing chain cover.
Fig.58CheckingOilPumpCoverFlatness
1 - FEELER GAUGE 2 - STRAIGHT EDGE 3 - OIL PUMP COVER
Measure thickness (Fig. 59) (Fig. 60) and diameter of rotors. If either rotor thickness measures 14.956
ENGINE 8.0L
9 - 400
OIL PUMP (Continued)DR
Fig.61MeasuringOuterRotorClearanceinCover 1 - FEELER GAUGE 2 - OUTER ROTOR
Fig.63MeasuringClearanceOverRotors
1 - FEELER GAUGE 2 - STRAIGHT EDGE
Fig.62MeasuringInnerRotorClearanceinCover 1 - FEELER GAUGE 2 - OUTER ROTOR 3 - INNER ROTOR
Inspect oil pressure relief valve plunger for scoring and free operation in its bore. Small marks may be removed with 400-grit wet or dry sandpaper.
The relief valve spring has a free length of approx- imately 49.5 mm (1.95 inches). The spring should test between 100 and 109 N (22.5 and 24.5 pounds) when compressed to 34 mm (1-11/32 inches). Replace spring that fails to meet these specifications.
If oil pressure was low and pump is within specifi- cations, inspect for worn engine bearings or other reasons for oil pressure loss.
INSTALLATION
(1) Lubricate both oil pump rotors using petroleum jelly or lubriplate and install in the timing chain cover. Use new parts as required (Fig. 64).
Fig.64PrimingOilPump.
1 - FILL WITH PETROLEUM JELLY OR LUBER PLATE
(2) Position the oil pump cover onto the timing chain cover. Tighten cover screws to 14 N·m (125 in. lbs.) torque.
(3) Make sure that inner ring moves freely after
cover is installed.
(4) Install the timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).
(5) Squirt oil into relief valve hole until oil runs
out.
(6) Install the relief valve and spring.
DR OIL PUMP (Continued)
(7) Using a new pressure relief valve gasket, install the relief valve plug. Tighten the plug to 20
N·m (15 ft. lbs.) torque.(8) Install oil filter that has been filled with oil.
INTAKE MANIFOLD DESCRIPTION
The aluminum intake manifold (Fig. 65) has two plenum chambers an upper and lower which supply air to five runners each. Passages across the longitu- dinal center of the manifold feed air from the throttle body to the plenum chambers.
Fig.65UpperandLowerIntakeManifold—8.0L
Engine
1 - UPPER INTAKE MANIFOLD 2 - THROTTLE BODY (MPI) 3 - LOWER INTAKE MANIFOLD
DIAGNOSIS AND TESTING—INTAKE MANIFOLD LEAKAGE
An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS, OR THE FAN. DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine. (2) Spray a small stream of water at the suspected
leak area.
ENGINE 8.0L
9 - 401
(3) If a change in RPMs occur, the area of the sus-
pected leak has been found.
(4) Repair as required.
REMOVAL
(1) Disconnect the negative cable from the battery. (2) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(3) Remove the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(4) Remove the generator brace and generator
(Fig. 66).
(5) Remove the A/C compressor brace (Fig. 66).
Remove the compressor and set aside.
Fig.66GeneratorandA/CCompressorBraces
1 - GENERATOR 2 - INTAKE MANIFOLD TO GENERATOR BRACE 3 - A/C COMPRESSOR 4 - INTAKE MANIFOLD TO A/C COMPRESSOR BRACE
(6) Remove the air
cover and filter. Remove the air cleaner housing (Fig. 67). Discard the gasket.
cleaner
(7) Perform the Fuel System Pressure release pro- cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV- ERY - STANDARD PROCEDURE). Disconnect the fuel lines (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STAN- DARD PROCEDURE).
(8) Disconnect the accelerator linkage and if so equipped, the speed control and transmission kick- down cables.
(9) Remove the coil assemblies with the ignition
wires.
(10) Disconnect the vacuum lines. (11) Disconnect the heater hoses and bypass hose. (12) Remove the closed crankcase ventilation and
evaporation control systems.
ENGINE 8.0L
9 - 402
INTAKE MANIFOLD (Continued)DR
Fig.67AirIntakeHousing
1 - AIR INTAKE HOUSING
Fig.69LowerIntakeManifold
(13) Remove the throttle body bolts and lift the throttle body off the upper intake manifold (Fig. 68). Discard the gasket.
(14) Remove upper intake manifold bolts. (15) Lift the upper intake manifold out of the
engine compartment (Fig. 68). Discard the gasket.
Fig.68UpperIntakeManifoldandThrottleBody
1 - UPPER INTAKE MANIFOLD 2 - THROTTLE BODY (MPI) 3 - LOWER INTAKE MANIFOLD
1 - INTAKE MANIFOLD GASKET 2 - SEALANT 3 - CROSS-OVER GASKETS 4 - SEALANT 5 - LOCATOR DOWELS
Fig.70LowerIntakeManifoldGaskets
(16) Remove the lower intake manifold bolts and
remove the manifold (Fig. 69).
(17) Discard the lower intake manifold gaskets
(Fig. 70).
CLEANING
pressed air.
able solvent.
Clean manifold in solvent and blow dry with com-
Clean cylinder block gasket surfaces using a suit-
The plenum pan rail must be clean and dry (free of
all foreign material).
INSPECTION
Inspect manifold for cracks. Inspect mating surfaces of manifold for flatness
with a straightedge.
INSTALLATION
(1) Install the intake manifold side gaskets. Be sure that the locator dowels are positioned in the head (Fig. 71).
DR INTAKE MANIFOLD (Continued)
ENGINE 8.0L
9 - 403
(15) Install the fuel lines (Refer to 14 - FUEL SYS- TEM/FUEL DELIVERY/QUICK CONNECT FIT- TING - STANDARD PROCEDURE).
(16) 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.
(17) Install the A/C compressor (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/A/C COMPRESSOR - INSTALLATION). Position the com- pressor brace and install the bolts. Tighten the brace bolts to 41 N·m (30 ft. lbs.) torque.
(18) Install the generator (Refer to 8 - ELECTRI- CAL/CHARGING/GENERATOR - INSTALLATION). Position the generator brace and install the bolts. Tighten the brace bolts to 41 N·m (30 ft. lbs.) torque. (19) Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(20) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(21) Connect the negative cable to the battery. (22) Start engine check for leaks.
EXHAUST MANIFOLD DESCRIPTION
Engine exhaust manifolds (Fig. 72) are made of high molybdenum ductile cast iron. A special ribbed design helps control permanent dimensional changes during heat cycles.
Fig.72ExhaustManifold—8.0LEngine
1 - EXHAUST MANIFOLD
OPERATION
The exhaust manifolds collect the engine exhaust exiting the combustion chambers, then channels the exhaust gases to the exhaust pipes attached to the manifolds.
Fig.71IntakeManifoldFlange
1 - LOCATOR DOWELS 2 - INTAKE MANIFOLD GASKETS 3 - LOCATOR DOWELS
(2) Insert Mopart GEN II Silicone Rubber Adhe- sive Sealant, or equivalent, into the four corner joints an excessive amount of sealant is not required to ensure a leak proof seal. However, an excessive amount of sealant may reduce the effectiveness of the flange gasket. The sealant should be approxi- mately 5 mm (0.2 in.) in diameter. (Fig. 70).
(3) Position the cross-over gaskets and press firmly onto the block (Fig. 70). BE SURE THE BLOCK IS OIL FREE..
(4) The lower intake manifold MUST be installed within 3 minutes of sealant application. Carefully lower intake manifold into position on the cylinder block and heads. After intake manifold is in place, inspect to make sure seals and gaskets are in place. Finger start all the lower intake bolts.
(5) Tighten the lower intake manifold bolts in lbs.) torque (Fig. 69). sequence to 54 N·m (40 ft. Recheck all bolts are tightened to 54 N·m (40 ft. lbs.) torque.
(6) Using a new gasket, position the upper intake
manifold onto the lower intake manifold.
(7) Finger start all bolts, alternate one side to the
other.
(8) Tighten upper
bolts sequence to 22 N·m (16 ft. lbs.) torque (Fig. 68).
intake manifold
in
(9) Using a new gasket, install the throttle body onto the upper intake manifold. Tighten the bolts to 23 N·m (200 in. lbs.) torque.
(10) Install closed crankcase ventilation and evap-
oration control systems.
(11) Connect the heater hoses and bypass hose. (12) Connect the vacuum lines. (13) Install the coil assemblies and the ignition
wires.
(14) Connect
the accelerator linkage and if so equipped, the speed control and transmission kick- down cables.
ENGINE 8.0L
9 - 404
EXHAUST MANIFOLD (Continued) REMOVAL(1) Disconnect the negative cable from the battery. (2) Raise and support the vehicle. (3) Remove the bolts and nuts attaching the
exhaust pipe to the engine exhaust manifold..
(4) Lower the vehicle. (5) Remove the exhaust heat shields (Fig. 73).
Fig.738.0LEngineExhaustManifold—Typical
1 - EXHAUST MANIFOLD 2 - HEAT SHIELD
(6) Remove the dipstick bracket from the exhaust
manifold (right side only).
(7) Remove bolts attaching manifold to cylinder head. (8) Remove manifold from the cylinder head. Dis-
card the gasket.
CLEANING
Clean mating surfaces on cylinder head and mani- fold. Wash with solvent and blow dry with com- pressed 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. Install bolts and stud bolts in the proper position. (Fig. 73) Tighten the bolts to 22 N·m (16 ft. lbs.) torque.
(2) Install the dipstick bracket on to the exhaust
manifold (right side only).
DR
(3) Position washers and exhaust heat shields onto the manifold stud bolts (Fig. 73). Be sure the tabs on the heat shields are hooked over the top of the exhaust gasket. Install the nuts and tighten to 20
N·m (175 in. lbs.) torque.(4) Raise and support the vehicle. (5) Assemble exhaust pipe to manifold. (6) Lower the vehicle. (7) Connect the negative cable to the battery. (8) Start engine check for leaks.
TIMING BELT / CHAIN COVER(S) REMOVAL
(1) Disconnect the negative cable from the battery. (2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove the serpentine belt (Refer to 7 - COOL- ING/ACCESSORY DRIVE/DRIVE BELTS - REMOV- AL).
(4) Remove fan and fan shroud (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL). (5) Unbolt A/C compressor and set on top of
engine.
assembly.
(6) Remove generator, air pump, and bracket
(7) Remove water pump (Refer to 7 - COOLING/
ENGINE/WATER PUMP - REMOVAL). (8) Remove damper bolt and washer. (9) Using Special Tool 1026 3-Jaw Puller remove
pulley/damper from the crankshaft. (Fig. 74)
(10) Loosen oil pan bolts and remove the front oil pan bolts that mount the pan to the timing chain cover.
(11) Remove the cover bolts. (12) Remove timing chain cover and gasket using
extreme caution to avoid damaging oil pan gasket.
(13) Inspect surface of cover. Remove any burrs or
high spots.
INSTALLATION
(1) Be sure mating surfaces of timing chain cover
and cylinder block are clean and free from burrs.
(2) Lubricate the pump rotors using petroleum jelly or lubriplate (Refer to 9 - ENGINE/LUBRICA- TION/OIL PUMP - INSTALLATION).
(3) Using a new cover gasket, carefully install tim- ing chain cover to avoid damaging oil pan gasket. Use a small amount of Mopart Silicone Rubber Adhe- sive Sealant, or equivalent, at the joint between tim- ing chain cover gasket and the oil pan gasket. Finger tighten the timing chain cover bolts at this time.
(4) Tighten timing chain cover bolts to 47 N·m (35
ft. lbs.) torque. Tighten oil pan bolts to 24 N·m (215
in. lbs.) torque.DR TIMING BELT / CHAIN COVER(S) (Continued)
ENGINE 8.0L
9 - 405
(7) Install water pump and housing assembly using new o-ring (Refer to 7 - COOLING/ENGINE/ WATER PUMP - INSTALLATION).
(8) Install generator, air pump, and bracket assem-
bly.
(9) Install A/C compressor (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/A/C COM- PRESSOR - INSTALLATION).
(10) (10) Install the radiator fan (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLA- TION).
(11) Position the fan shroud and install the bolts.
Tighten the bolts to 11 N·m (95 in. lbs.) torque.
(12) Install the serpentine belt (Refer to 7 - COOL- ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL- LATION).
(13) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(14) Connect the negative cable to the battery. (15) Road test vehicle and check for leaks.
Fig.74Pulley—DamperRemoval
1 - 3 JAW PULLER
(5) Using Special Tool C-3688 Crankshaft Pulley/ Damper Installer Install pulley/vibration damper (Fig. 75)
Fig.75InstallingCrankshaft
1 - SPECIAL TOOL C-3688
(6) Prime oil pump by squirting oil in the oil filter mounting hole and filling the J-trap of the front tim- ing cover. When oil is running out, install oil filter that has been filled with oil.
TIMING BELT/CHAIN AND SPROCKETS REMOVAL
(1) Remove timing chain cover and gasket using extreme caution to avoid damaging oil pan gasket (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). camshaft and crankshaft
centerline. Remove camshaft sprocket attaching bolt and remove timing chain and camshaft sprockets.
(2) Aline
(3) Use puller 6444 and jaws 6820 to remove
crankshaft sprocket (Fig. 76).
INSPECTION—MEASURING TIMING CHAIN STRETCH
(1) Place a scale next to the timing chain so that
any movement of the chain may be measured.
(2) Place a torque wrench and socket over cam- shaft sprocket attaching bolt. Apply torque in the direction of crankshaft rotation to take up slack; 41
N·m (30 ft. lbs.) torque with cylinder head installed or 20 N·m (15 ft. lbs.) torque with cylinder head removed. With a torque applied to the camshaft sprocket bolt, crankshaft should not be permitted to move. It may be necessary to block the crankshaft to prevent rotation.(3) Hold a scale with dimensional reading even with the edge of a chain link. With cylinder heads installed, apply 14 N·m (30 ft. lbs.) torque in the reverse direction. With the cylinder heads removed, apply 20 N·m (15 ft. lbs.) torque in the reverse direc- tion. Note the amount of chain movement (Fig. 77).
ENGINE 8.0L
9 - 406
TIMING BELT/CHAIN AND SPROCKETS (Continued)DR
Fig.76CrankshaftSprocketRemoval.
1 - SPECIAL TOOL 6444
2 - SPECIAL TOOL 6820Fig.78CrankshaftSprocketInstallation
1 - SPECIAL TOOL C-3688
2 - SPECIAL TOOL C-3718
3 - SPECIAL TOOL MD990799Fig.77MeasuringTimingChainStretch
1 - TORQUE WRENCH 2 - 3.175 MM (0.125 IN.)
(4) Install a new timing chain,
exceeds 3.175 mm (1/8 inch).
if its movement
INSTALLATION
(1) Line up key in crankshaft with keyway in sprocket, press on crankshaft timing sprocket, use tools C-3688, C-3718 and MB-990799, seat sprocket against crankshaft shoulder (Fig. 78).
(2) Turn crankshaft to line up the timing mark
with the crankshaft and camshaft centerline.
(3) Put chain on camshaft sprocket. (4) Align timing marks and install chain and cam- shaft sprocket onto crankshaft sprocket. Check to see that timing marks are on the centerline of the crank- shaft and camshaft centerline (Fig. 79).
Fig.79AlignmentofTimingMarks
1 - CAMSHAFT SPROCKET 2 - CRANKSHAFT SPROCKET 3 - TIMING MARKS
(5) Install the camshaft bolt. Tighten the bolt to 61
N·m (45 ft. lbs.) torque.
(6) Check camshaft end play. The end play should be 0.051-0.152 mm (0.002-0.006 inch) with a new thrust plate and up to 0.254 mm (0.010 inch) with a used thrust plate. If not within these limits install a new thrust plate.
(7) Install
timing chain cover
to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).
(Refer
DR
EXHAUST SYSTEM 11 - 1
EXHAUST SYSTEM
TABLE OF CONTENTS
page
page
EXHAUST SYSTEM
DESCRIPTION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MUFFLER
DESCRIPTION DESCRIPTION – 5.9L DIESEL
. . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . 2REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - GAS ENGINE . . . 2
DIAGNOSIS AND TESTING - DIESELENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS - TORQUE . . . . . . . . . . . . . . . 4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 4CATALYTIC CONVERTER
DESCRIPTION - CATALYTIC CONVERTER . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVALREMOVAL REMOVAL INSPECTION INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . 5INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 5EXHAUST PIPE
REMOVAL
REMOVAL — 5.9L REMOVAL INSPECTION INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . 6. . . . . . . . . . . . . . . . . . 6
INSTALLATION — 5.9L INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 7EXHAUST PIPE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSPECTION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7HEAT SHIELDS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7EXHAUST SYSTEM
DESCRIPTION
DESCRIPTION
CAUTION: Avoid application of rust prevention com- pounds or undercoating materials to exhaust sys- tem floor pan exhaust heat shields. Light overspray near the edges is permitted. Application of coating will result in excessive floor pan temperatures and objectionable fumes.
MUFFLER - 5.9L DIESEL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9TAILPIPE - 5.9L DIESEL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSPECTION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9TAILPIPE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10TURBOCHARGER SYSTEM
DIAGNOSIS AND TESTING -
TURBOCHARGER BOOST PRESSURE . . . . . 10
TURBOCHARGER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14CHARGE AIR COOLER AND PLUMBING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING - CHARGE AIRCOOLER SYSTEM - LEAKS . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16The federal gasoline engine exhaust system con- sists of engine exhaust manifolds, exhaust pipes, cat- alytic (if needed), exhaust heat shields, muffler and exhaust tailpipe.
extension pipe
converter(s),
The California emission vehicles exhaust system also contains the above components as well as mini catalytic converters added to the exhaust pipe.
The exhaust system must be properly aligned to prevent stress, leakage and body contact. Minimum clearance between any exhaust component and the body or frame is 25.4 mm (1.0 in.). If the system con- tacts any body panel, it may amplify objectionable noises from the engine or body.
EXHAUST SYSTEM
11 - 2
EXHAUST SYSTEM (Continued) DESCRIPTION – 5.9L DIESELCAUTION: Avoid application of rust prevention com- pounds or undercoating materials to exhaust sys- tem floor pan exhaust heat shields. Light overspray near the edges is permitted. Application of coating will result in excessive floor pan temperatures and objectionable fumes.
The diesel engine exhaust system consists of an engine exhaust manifold, turbocharger, exhaust pipe,
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - GAS ENGINE
DR
resonator, extension pipe (if needed), muffler and exhaust tailpipe.
California emission vehicales include a catalytic
converter.
stress,
The exhaust system must be properly aligned to prevent leakage and body contact. The exhaust components should be kept a minimum of 25.4 mm (1.0 in.) away from the body and frame. If the system contacts any body panel, it may amplify objectionable noises from the engine or body.
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION
POSSIBLE CAUSE
CORRECTION
EXCESSIVE EXHAUST NOISE OR LEAKING EXHAUST GASES
1. Leaks at pipe joints.
2. Rusted or blown out muffler.
3. Broken or rusted out exhaust pipe. 4. Exhaust pipe leaking at manifold flange. 5. Exhaust manifold cracked or broken. 6. Leak between exhaust manifold and cylinder head. 7. Catalytic converter rusted or blown out. 8. Restriction in exhaust system.
1. Tighten clamps/bolts at leaking joints. 2. Replace muffler. Inspect exhaust system. 3. Replace exhaust pipe.
4. Tighten/replace flange attaching nuts/bolts. 5. Replace exhaust manifold.
6. Tighten exhaust manifold to cylinder head bolts. 7. Replace catalytic converter assy.
8. Remove restriction, if possible. Replace restricted part if necessary.
CAUTION: When servicing and 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.
DR EXHAUST SYSTEM (Continued) DIAGNOSIS AND TESTING - DIESEL ENGINE
EXHAUST SYSTEM 11 - 3
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION
POSSIBLE CAUSE
CORRECTION
EXCESSIVE EXHAUST NOISE OR
1. Leaks at pipe joints.
LEAKING EXHAUST GASES
2. Rusted or blown out muffler.
3. Broken or rusted out exhaust pipe. 4. Exhaust pipe leaking at manifold flange. 5. Exhaust manifold cracked or broken. 6. Leak between exhaust manifold and cylinder head.
7. Turbocharger mounting flange cracked.
8. Restriction in exhaust system.
1. Tighten clamps/bolts at leaking joints. 2. Replace muffler. Inspect exhaust system. 3. Replace exhaust pipe.
4. Tighten/replace flange attaching nuts/bolts. 5. Replace exhaust manifold.
6. Tighten exhaust manifold to cylinder head bolts. Replace gasket if necessary. 7. Remove turbocharger and inspect. (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYSTEM/TURBOCHARGER - REMOVAL). 8. Remove restriction, if possible. Replace restricted part if necessary.
EXHAUST SYSTEM
11 - 4
EXHAUST SYSTEM (Continued) SPECIFICATIONS - TORQUESPECIAL TOOLS
DR
DESCRIPTION
N·m
Ft.
Lbs. — —
18
1835
In.
Lbs. 200
124— —
—
23
1424
2448
Adjusting Strap—Bolt
Air Heater Power Supply—
Nuts
Air Inlet Housing—Bolts
Cab Heater Supply/Return
Line—Nuts
Exhaust Clamp—Nuts
Exhaust Manifold to Cylinder
Head—Bolts
(Diesel Engine) Exhaust Manifold to Cylinder
Head—Bolts
(5.9L) Exhaust Manifold to Cylinder
Head—Bolts
(8.0L) Exhaust Pipe to Manifold—
Bolts
Generator Mounting—Bolts
Charge Air Cooler Mounting—Bolts
Charge Air Cooler Duct—
Nuts
Heat Shield—Nuts and Bolts Turbocharger flange studs Turbocharger Mounting—
Nuts
Turbocharger Oil Drain
Tube—Bolts
Turbocharger Oil Supply
Line—Fitting
Turbocharger V-Band
Clamp—Nut
Turbocharger Oil Supply fitting (at Turbocharger) Turbocharger Oil Supply fitting (at lube filter head) Turbocharger Drain Hose
Clamps
43
32
—
31
23
—
22
3141
11
11
24
4324
24
36
24
— 23
30
——
— 18
3218
18
—
27
18
—
195
—— 17
95
95
— ——
—
75
—
—
71
TURBOCHARGERTESTER9022
CATALYTIC CONVERTER DESCRIPTION - CATALYTIC CONVERTERWARNING: THE NORMAL OPERATING TEMPERA- TURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CON- VERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME.
CAUTION: DO NOT remove spark plug wires from plugs or by any other means short out cylinders. Failure of the catalytic converter can occur due to a temperature increase caused by unburned fuel passing through the converter.
The stainless steel catalytic converter body is designed to last the life of the vehicle. Excessive heat can result in bulging or other distortion, but exces- sive heat will not be the fault of the converter. If unburned fuel enters the converter, overheating may occur. If a converter is heat-damaged, correct the cause of the damage at the same time the converter is replaced. Also, inspect all other components of the exhaust system for heat damage.
Unleaded gasoline must be used to avoid con-
taminating the catalyst core.
50 State emission vehicles incorporate two mini catalytic converters located after the exhaust mani- folds and before the inline catalytic converter.
OPERATION
The catalytic converter captures and burns any unburned fuel mixture exiting the combustion cham- bers during the exhaust stroke of the engine. This process aids in reducing emissions output.
DR CATALYTIC CONVERTER (Continued) REMOVAL
REMOVAL
WARNING: IF TORCHES ARE USED WHEN WORK- ING ON THE EXHAUST SYSTEM, DO NOT ALLOW THE FLAME NEAR THE FUEL LINES.
(1) Raise and support the vehicle. (2) Saturate the bolts and nuts with heat valve
lubricant. Allow 5 minutes for penetration.
(3) Remove the bolts from the crossover pipe to the
catalytic converter connection.
(4) Disconnect oxygen sensor wiring. (5) Loosen the nuts from the clamp that hold the catalytic converter to the exhaust pipe flange connec- tion.
NOTE: Do not remove nut from T-Bolt. Only remove nut far enough, so that the T end can be removed from the clamp.
(6) Remove the T bolt end of the fastener, from the
clamp.
(7) Spread the clamp, and remove the catalytic
converter from the vehicle.
(8) Discard the clamp.
NOTE: The catalytic converter to exhaust manifold clamp is not reusable. Always use a new clamp when reinstalling the catalytic converter.
REMOVAL
(1) Raise and support vehicle. (2) Saturate the bolts and nuts with heat valve
lubricant. Allow 5 minutes for penetration.
(3) Remove clamps and nuts. (4) Remove the catalytic converter.
INSPECTION
Look at the stainless steel body of the converter, inspect for bulging or other distortion that could be a result of overheating. If the converter has a heat shield attached make sure it is not bent or loose.
If you suspect internal damage to the catalyst, tap- ping the bottom of the catalyst with a rubber mallet may indicate a damaged core.
INSTALLATION
INSTALLATION
NOTE: The catalytic converter to exhaust manifold clamp is not reusable. Always use a new clamp when reinstalling the catalytic converter.
EXHAUST SYSTEM 11 - 5
(1) Position the
the exhaust pipe flange connection. Tighten the nuts to 28 N·m (250 in. lbs.) torque.
converter
catalytic
onto
(2) Install the muffler onto the catalytic converter until the alignment tab is inserted into the align- ment slot.
(3) Install the exhaust clamp at the muffler and catalytic converter connection. Tighten the clamp nuts to 47 N·m (35 ft. lbs.) torque.
(4) Connect oxygen sensor wiring. (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.
INSTALLATION
(1) Assemble converter and clamps loosely in
place.
torque.
(2) Install the exhaust pipe onto exhaust mani-
folds, tighten 31 N·m (23 ft. lbs.).
(3) Tighten all clamp nuts to 48 N·m (35 ft. lbs.)
(4) Lower the vehicle. (5) Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. A minimum of 25.4 mm (1.0 in.) is required between exhaust system components and body/frame parts. Adjust the alignment, if needed.
EXHAUST PIPE
REMOVAL
REMOVAL — 5.9L
(1) Raise and support the vehicle. (2) Saturate the bolts and nuts with heat valve
lubricant. Allow 5 minutes for penetration.
(3) Remove exhaust pipe to manifold bolts, retain-
ers and nuts.
(4) Remove the clamp nuts. (5) Remove the exhaust pipe (Fig. 1).
REMOVAL
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.
(1) Raise and support the vehicle. (2) Saturate the bolts and nuts with Mopart Rust
Penetrant. Allow 5 minutes for penetration.
(3) Disconnect the oxygen sensor(s).
EXHAUST SYSTEM
11 - 6
EXHAUST PIPE (Continued)DR
INSPECTION
Discard rusted clamps, broken or worn supports and attaching parts. Replace a component with orig- inal equipment parts, or equivalent. This will assure proper alignment with other parts in the system and provide acceptable exhaust noise levels.
INSTALLATION
INSTALLATION — 5.9L
(1) Position the exhaust pipe for proper clearance with the frame and underbody parts. A minimum clearance of 25.4 mm (1.0 in.) is required.
(2) Position the exhaust pipe to manifold. Install the bolts, retainers and nuts. Tighten the nuts to 31
N·m (23 ft. lbs.) torque.(3) Tighten the clamp nuts to 48 N·m (35 ft. lbs.)
torque.
(4) Lower the vehicle. (5) Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed (Fig. 1) and (Fig. 3).
Fig.1ExhaustPipetoManifoldConnection–5.9L 1 - BOLT 2 - RETAINER 3 - EXHAUST MANIFOLD 4 - NUT 5 - EXHAUST PIPE
(4) Remove the exhaust manifold-to-exhaust pipe
(5) Remove exhaust pipe to converter exhaust
nuts (Fig. 2).
clamp.
(6) Disconnect the exhaust pipe from the catalytic
converter front flange.
(7) Remove the exhaust pipe.
Fig.3ExhaustPipe-to-CatalyticConverterFlange
Alignment—Typical
1 - 7.874–17.526 mm (0.31–0.69 in.) 2 - CATALYTIC CONVERTER FLANGE 3 - 20 mm (0.79 in.) MIN. 4 - CROSSMEMBER 5 - EXHAUST PIPE 6 - EXHAUST PIPE
Fig.2ExhaustPipe(s)toManifoldConnection
1 - BOLT 2 - RETAINER 3 - EXHAUST MANIFOLD 4 - NUT 5 - EXHAUST PIPE
DR EXHAUST PIPE (Continued) INSTALLATION
EXHAUST SYSTEM 11 - 7
(1) Connect the exhaust pipe(s) to the exhaust manifold. Tighten the nuts to 34 N·m (25 ft. lbs.) torque.
(2) Align and connect the exhaust pipe to the cat- alytic converter flange (Fig. 4). Install exhaust clamp and tighten clamp nuts to 47 N·m (35 ft. lbs.) torque.
(3) Connect oxygen sensor connector(s). (4) Lower the vehicle. (5) Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed.
Fig.5ExhaustPipe
1 - Clamp 2 - Support 3 - EXHAUST PIPE
INSTALLATION
Fig.4ExhaustPipe-to-CatalyticConverterFlange
Alignment—Typical
1 - 7.874–17.526 mm (0.31–0.69 in.) 2 - CATALYTIC CONVERTER FLANGE 3 - 20 mm (0.79 in.) MIN. 4 - CROSSMEMBER 5 - EXHAUST PIPE 6 - EXHAUST PIPE
EXHAUST PIPE REMOVAL
(1) Disconnect the battery negative cables. (2) Raise and support the vehicle on a hoist. (3) Saturate the bolts and nuts with heat valve
lubricant. Allow 5 minutes for penetration.
(4) Remove the exhaust pipe-to-extension pipe clamp. Separate the exhaust pipe and extension pipe. (5) Remove the exhaust pipe-to-turbocharger elbow
clamp (Fig. 5).
sion support (Fig. 5).
(6) Remove the exhaust pipe from the transmis-
INSPECTION
Discard rusted clamps, broken or worn supports and attaching parts. Replace a component with orig- inal equipment parts, or equivalent. This will assure proper alignment with other parts in the system and provide acceptable exhaust noise levels.
(1) Install the exhaust pipe into the transmission
support and onto the turbocharger flange.
(2) Install the exhaust pipe-to-turbocharger elbow
clamp and tighten to 31 N·m (23 ft. lbs.) torque.
(3) Install the extension pipe and clamp to the exhaust pipe using a new clamp and tighten the clamp nuts to 48 N·m (35 ft. lbs.) torque.
(4) Lower the vehicle. (5) Connect the battery negative cables. (6) Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. A minimum of 25.4 mm (1.0 in.) is required. Adjust the alignment, if needed.
HEAT SHIELDS DESCRIPTION
There are two types of heat shields used. One is stamped steel the other is molded foil sheets. The shields attach to the vehicle around the exhaust sys- tem to prevent heat from the exhaust system from entering the passenger area and other areas where the heat can cause damage to other components.
REMOVAL
(1) Raise and support the vehicle. (2) Remove the nuts or bolts holding the exhaust heat shield to the floor pan (Fig. 6) (Fig. 7) (Fig. 8), crossmember or bracket.
EXHAUST SYSTEM
11 - 8
HEAT SHIELDS (Continued)DR
Fig.6HEATSHIELDS-RH-REGCAB
1 - HEAT SHIELD 2 - FASTENER 3 - NUT 4 - HEAT SHIELD
Fig.8HEATSHIELDLH
1 - HEAT SHIELD 2 - NUT
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 11 N·m (100 in.
lbs.).
(3) Lower the vehicle.
MUFFLER REMOVAL
(1) Raise and support the vehicle. (2) Saturate the clamp nuts with heat valve lubri-
cant. Allow 5 minutes for penetration.
(3) Disconnect the muffler hangers (Fig. 9). (4) Remove clamps and nuts. (5) Remove the muffler.
INSTALLATION
(1) Assemble muffler and clamps loosely to permit
proper alignment of all parts.
(2) Connect the muffler hangers. (3) Tighten the clamp nuts to 48 N·m (35 ft. lbs.)
torque.
Fig.7HEATSHIELDS-RH-QUADCAB
1 - HEAT SHIELD 2 - FASTENER 3 - NUT 4 - HEAT SHIELD
(3) Slide the shield out around the exhaust system.
(4) Lower the vehicle. (5) Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. A minimum of 25.4 mm (1.0 in.) is required between exhaust system components and body/frame parts. Adjust the alignment, if needed.
DR MUFFLER (Continued)
EXHAUST SYSTEM 11 - 9
Fig.9MUFFLER
Fig.10MufflerRemoval/Installation
1 - INSULATOR 2 - INSULATOR 3 - MUFFLER 4 - INSULATOR
MUFFLER - 5.9L DIESEL REMOVAL
(1) Disconnect the battery negative cables. (2) Raise and support the vehicle. (3) Remove the muffler to tail pipe and extension
pipe clamps (Fig. 10).
tors (Fig. 10).
(4) Disconnect the muffler from the hanger isola-
(5) Disconnect the muffler from the tailpipe. (6) Disconnect the muffler from the extension pipe
and remove from the vehicle.
INSTALLATION
tors (Fig. 10).
(1) Install the muffler hanger rods into the isola-
(2) Install the muffler into the extension pipe. (3) Install the muffler into the tail pipe. (4) Install the exhaust clamps, align the exhaust system, and tighten the exhaust clamps to 48 N·m (35 ft. lbs.) torque.
(5) Lower the vehicle. (6) Connect the battery negative cables. (7) Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. A minimum of 25.4 mm (1.0 in.) is required between exhaust system components and body/frame parts. Adjust the alignment, if needed.
1 - INSULATOR 2 - ISOLATOR 3 - TAILPIPE 4 - CLAMP 5 - MUFFLER 6 - CLAMP 7 - EXTENSION PIPE
TAILPIPE - 5.9L DIESEL REMOVAL
(1) Disconnect the battery negative cables. (2) Raise and support the vehicle. (3) Saturate the clamp nuts with heat valve lubri-
cant. Allow 5 minutes for penetration.
(4) Disconnect the exhaust tailpipe support hanger
isolators (Fig. 11).
(5) Remove the muffler-to-tailpipe clamps (Fig. 11). (6) Remove the tailpipe from the vehicle.
INSPECTION
Discard rusted clamps, broken or worn supports and attaching parts. Replace a component with orig- inal equipment parts, or equivalent. This will assure proper alignment with other parts in the system and provide acceptable exhaust noise levels.
INSTALLATION
(1) Install the tailpipe into the muffler. (2) Install the tailpipe hanger rods into the isola-
tors (Fig. 11)
(3) Install the exhaust clamp, align the exhaust system, and tighten the clamp 48 N·m (35 ft. lbs.) torque.
EXHAUST SYSTEM
11 - 10
TAILPIPE - 5.9L DIESEL (Continued)DR
Fig.11TailpipeRemoval/Installation
Fig.12TAILPIPE
1 - ISOLATOR 2 - TAILPIPRE 3 - CLAMP 4 - MUFFLER
(4) Lower the vehicle. (5) Connect the battery negative cables. (6) Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed.
TAILPIPE REMOVAL
(1) Raise and support the vehicle. (2) Saturate the clamp nuts with heat valve lubri-
cant. Allow 5 minutes for penetration.
(3) Disconnect the exhaust tailpipe support hanger
(Fig. 12).
(4) Remove clamps and nuts. (5) Remove the exhaust tailpipe.
INSPECTION
Discard rusted clamps, broken or worn supports and attaching parts. Replace a component with orig- inal 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 to permit
proper alignment of all parts.
(2) Connect the support hangers.
1 - INSULATOR 2 - TAILPIPE 3 - CLAMP 4 - MUFFLER 5 - CLAMP 6 - INSULATOR 7 - INSULATOR 8 - INSULATOR
(3) Position the exhaust tailpipe for proper clear-
ance with the underbody parts.
(4) Tighten all clamp nuts to 48 N·m (35 ft. lbs.)
torque.
(5) Lower the vehicle. (6) Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. A minimum of 25.4 mm (1.0 in.) is required between the exhaust system components and body/frame parts. Adjust the alignment, if needed.
TURBOCHARGER SYSTEM DIAGNOSIS AND TESTING - TURBOCHARGER BOOST PRESSURE
NOTE: This diagnostic procedure is to be used with the DRB IIIT while test driving the vehicle under normal load and driving conditions.
Low turbocharger boost pressure can cause poor engine performance and driveability concerns. The following procedure will test the turbocharger boost pressure.
DR TURBOCHARGER SYSTEM (Continued)
(1) Loosen clamps holding air inlet duct rubber sleeve to the intake manifold and air inlet duct. Remove rubber sleeve (Fig. 13).
EXHAUST SYSTEM 11 - 11
† Turbocharger damaged (Refer to 11 - EXHAUST SYSTEM/TURBO-
SYSTEM/TURBOCHARGER CHARGER - INSPECTION)
TURBOCHARGER DESCRIPTION
The turbocharger is an exhaust-driven supercharger which increases the pressure and density of the air entering the engine. With the increase of air entering the engine, more fuel can be injected into the cylin-
