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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- ders, which creates more power during combustion.
major component systems (Fig. 14) (Fig. 15) :
The turbocharger assembly consists of † Turbine section † Compressor section † Bearing housing † Wastegate
four (4)
Fig.13INTAKEMANIFOLDTOAIRINLETDUCT
RUBBERSLEEVE
1 - INTAKE MANIFOLD AIR INLET 2 - CLAMPS 3 - AIR INLET DUCT 4 - AIR INLET DUCT RUBBER SLEEVE
(2) Position Special Tool 8462 onto air inlet duct and intake manifold. Using the existing clamps tighten to 8 N·m (72 in. lbs.).
(3) Install the 3447.5 kPa 500 psi (gray) Pressure Transducer (part of OT-CH8520 Transducer Kit) into Special Tool 8462.
(4) Connect the DRB IIIt to the pressure trans- ducer following the instructions supplied with the DRB IIIt.
(5) Enter DRB IIIt into pressure reading mode
and test drive vehicle.
(6) Full laod boost pressure at rated speed will be 158 - 186 kPa (23 - 27 psi.) depending on engine hp rating.. If pressure readings are are not within this range inspect for the following: † Restricted air inlet system † Leak in the charge air cooler system (Refer to 11
- EXHAUST SYSTEM/TURBOCHARGER SYSTEM/ CHARGE AIR COOLER AND PLUMBING - DIAG- NOSIS AND TESTING) † Turbocharger wastegate broken or misadjusted † Restricted/high pressure drop across charge air coolerFig.14TurbochargerOperation
1 - TURBINE SECTION 2 - EXHAUST GAS 3 - BEARING HOUSING 4 - COMPRESSOR SECTION 5 - INLET AIR 6 - COMPRESSED AIR TO ENGINE 7 - EXHAUST GAS 8 - EXHAUST GAS TO EXHAUST PIPE
OPERATION
Exhaust gas pressure and energy drive the tur- bine, which in turn drives a centrifugal compressor that compresses the inlet air, and forces the air into the engine through the charge air cooler and plumb- ing. Since heat is a by-product of this compression, the air must pass through a charge air cooler to cool the incoming air and maintain power and efficiency.
Increasing air flow to the engine provides: † Improved engine performance † Lower exhaust smoke density
EXHAUST SYSTEM
11 - 12
TURBOCHARGER (Continued)DR
Fig.15TurbochargerWastegateActuator
1 - TURBOCHARGER 2 - DIAPHRAGM 3 - WASTE GATE ACTUATOR
† Improved operating economy † Altitude compensation † Noise reduction. The turbocharger also uses a wastegate (Fig. 16), which regulates intake manifold air pressure and prevents over boosting at high engine speeds. When the wastegate valve is closed, all of the exhaust gases flow through the turbine wheel. As the intake mani- fold pressure increases, the wastegate actuator opens the valve, diverting some of the exhaust gases away from the turbine wheel. This limits turbine shaft speed and air output from the impeller.
The turbocharger is lubricated by engine oil that is pressurized, cooled, and filtered. The oil is delivered to the turbocharger by a supply line that is tapped into the oil filter head. The oil travels into the bear- ing housing, where it lubricates the shaft and bear- ings (Fig. 17). A return pipe at the bottom of the bearing housing, routes the engine oil back to the crankcase.
The most common turbocharger failure is bearing failure related to repeated hot shutdowns with inade- quate “cool-down” periods. A sudden engine shut down
Fig.16WastegateOperation
1 - SIGNAL LINE 2 - EXHAUST BYPASS VALVE 3 - WASTEGATE 4 - EXHAUST 5 - TURBINE
after prolonged operation will result in the transfer of heat from the turbine section of the turbocharger to the bearing housing. This causes the oil to overheat and break down, which causes bearing and shaft dam- age the next time the vehicle is started.
Letting the engine idle after extended operation allows the turbine housing to cool to normal operat- ing temperature. The following chart should be used as a guide in determining the amount of engine idle time required to sufficiently cool down the turbo- charger before shut down, depending upon the type of driving and the amount of cargo.
DR TURBOCHARGER (Continued)
EXHAUST SYSTEM 11 - 13
Fig.18TurbochargerAirInletHose
1 - AIR INLET TUBE 2 - AIR FILTER HOUSING 3 - TURBOCHARGER
Fig.17TurbochargerOilSupplyandDrain
1 - BEARINGS 2 - OIL SUPPLY (FROM FILTER HEAD) 3 - OIL RETURN (TO SUMP)
TURBOCHARGER (COOL DOWN( CHART
Turbocharger
Idle Time (in
minuetes) Temperature Before Shut
Cool Warm Warm
Warm
Warm
Hot
Down
Less than 1
Driving
Load
Condition
Empty Stop & Go Stop & Go Medium Highway Medium Speeds
Max. GCWR Max. GCWR Max. GCWR
City Traffic
Highway Speeds Uphill Grade
REMOVAL
(1) Disconnect the battery negative cables. (2) Raise vehicle on hoist. (3) Disconnect the exhaust pipe from the turbo- charger elbow(Refer to 11 - EXHAUST SYSTEM/EX- HAUST PIPE - REMOVAL).
(4) Lower vehicle. (5) Disconnect the turbocharger air inlet hose (Fig.
18).
(6) Disconnect the turbocharger oil supply line and
the oil drain tube from the turbocharger (Fig. 19).
(7) Disconnect the charge air cooler inlet pipe from
the turbocharger compressor outlet (Fig. 19).
(8) Remove the turbocharger and gasket from the
exhaust manifold.
Fig.19OilSupplyLineandChargeAirCoolerInlet
Duct
1 - TURBOCHARGERR EXHAUST ELBOW 2 - TURBOCHARGER 3 - OIL SUPPLY LINE 4 - AIR INLET TUBE 5 - TURBOCHARGER COMPRESSOR OUTLET 6 - OIL DRAIN LINE
EXHAUST SYSTEM
11 - 14
TURBOCHARGER (Continued)DR
(9) If the turbocharger is not to be installed imme- diately, cover the opening to prevent material from entering into the manifold.
(10) If replacing the turbocharger, transfer the
compressor outlet and clamp to the new assembly.
(11) Clean and inspect the sealing surface.
CAUTION: The turbocharger is only serviced as an assembly. Do not attempt to repair the turbocharger as turbocharger and/or engine damage can result.
CLEANING
Clean the turbocharger and exhaust manifold
mounting surfaces with a suitable scraper.
INSPECTION
Visually inspect
the turbocharger and exhaust manifold gasket surfaces. Replace stripped or eroded mounting studs.
that go completely through.
The following cracks are NOT acceptable:
(1) Visually inspect the turbocharger for cracks. † Cracks in the turbine and compressor housing † Cracks in the mounting flange that are longer † Cracks in the mounting flange that intersect † Two (2) Cracks in the mounting flange that are
than 15 mm (0.6 in.).
bolt through-holes.
closer than 6.4 mm (0.25 in.) together.
(2) Visually inspect the impeller and compressor wheel fins for nicks, cracks, or chips. Note: Some impellers may have a factory placed paint mark which, after normal operation, appears to be a crack. Remove this mark with a suitable solvent to verify that it is not a crack.
(3) Visually inspect the turbocharger compressor housing for an impeller rubbing condition (Fig. 20). Replace the turbocharger if the condition exists. (4) Measure the turbocharger axial end play:
(a) Install a dial indicator as shown in (Fig. 21).
Zero the indicator at one end of travel.
(b) Move the impeller shaft fore and aft and record the measurement. Allowable end play is 0.026 mm (0.0001 in.) MIN. and 0.127 mm (0.005
in.) MAX. If the recorded measurement falls out- side these parameters, replace the turbocharger assembly. (5) Measure the turbocharger bearing radial clear-ance:
(a) Insert a narrow blade or wire style feeler gauge between the compressor wheel and the hous- ing (Fig. 22).
(b) Gently push the compressor wheel toward
the housing and record the clearance.
(c) With the feeler gauge in the same location, gently push the compressor wheel away from the housing and again record the clearance.
(d) Subtract
the smaller clearance from the larger clearance. This is the radial bearing clear- ance.
(e) Allowable radial bearing clearance is 0.33
mm (0.013 in.) MIN. and 0.50 mm (0.020 in.) MAX. If the recorded measurement falls outside these specifications, replace the turbocharger assembly.Fig.20InspectCompressorHousingforImpeller
RubbingCondition
Fig.21MeasureTurbochargerAxialEndPlay
INSTALLATION
(1) Install the turbocharger. Apply anti-seize to the studs and then tighten the turbocharger mounting nuts to 43 N·m (32 ft. lbs.) torque.
(2) Install the oil drain tube to the turbocharger (Fig. 19). Tighten the drain tube bolts to 24 N·m (18
ft. lbs.) torque.DR TURBOCHARGER (Continued)
EXHAUST SYSTEM 11 - 15
Fig.22MeasureTurbochargerBearingRadial
Clearance
1 - FEELER GAUGE
(3) Pre-lube the turbocharger. Pour 50 to 60 cc (2 to 3 oz.) clean engine oil in the oil supply line fit- ting. Carefully rotate the turbocharger impeller by hand to distribute the oil thoroughly.
(4) Install and tighten the oil supply line to 24
N·m (18 ft. lbs.) torque.
(5) Position the charge air cooler inlet pipe to the turbocharger. With the clamp in position, tighten the clamp nut to 11 N·m (95 in. lbs.) torque.
(6) Position the air inlet hose to the turbocharger (Fig. 18). Tighten the clamp to 11 N·m (95 in. lbs.) torque.
(7) Raise vehicle on hoist. (8) Connect the exhaust pipe to the turbocharger and tighten the bolts to 34 N·m (25 ft. lbs.) torque.
(9) Lower the vehicle. (10) Connect the battery negative cables. (11) Start the engine to check for leaks.
CHARGE AIR COOLER AND PLUMBING DESCRIPTION
The charge air system (Fig. 23) consists of the charge air cooler piping, charge air cooler and intake air grid heater.
The charge air cooler is a heat exchanger that uses air flow from vehicle motion to dissipate heat from the intake air. As the turbocharger increases air pressure, the air temperature increases. Lowering the intake air temperature increases engine effi- ciency and power.
Fig.23IntakeAirCirculation
1 - CHARGE AIR COOLER 2 - AIRFILTER 3 - TURBOCHARGER
ized air from the turbocharger then flows forward through the charge air cooler located in front of the radiator. From the charge air cooler the air flows back into the intake manifold.
DIAGNOSIS AND TESTING - CHARGE AIR COOLER SYSTEM - LEAKS
Low turbocharger boost pressure and low engine performance can be caused by leaks in the charge air cooler or it’s plumbing. Fuel staining on the exhaust manifold can also be an indication that there are leaks in the air system.The following procedure out- lines how to check for leaks in the charge air cooler system.
(1) Loosen clamp and remove air inlet hose from
turbocharger.
(2) Insert Special Tool 9022 Adapter into the turbo- charger inlet. Tighten tool clamp to 8 N·m (72 in. lbs.).
CAUTION: Do not apply more than 138 kPa (20 psi) air pressure to the charge air cooler system, sever damage to the charge air cooler system may occur.
(3) Connect a regulated air supply to air fitting on Special Tool 9022 Adapter. Set air pressure to a Max- imum of 138 kPa (20 psi).
(4) Using soapy water check the rubber sleeves,
charge air cooler and intake manifold for leaks.
REMOVAL
OPERATION
Intake air is drawn through the air cleaner and into the turbocharger compressor housing. Pressur-
WARNING: IF THE ENGINE WAS JUST TURNED OFF, THE AIR INTAKE SYSTEM TUBES MAY BE HOT.
EXHAUST SYSTEM
11 - 16
CHARGE AIR COOLER AND PLUMBING (Continued)DR
(1) Disconnect the battery negative cables. (2) Discharge the A/C system (Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING - STAN- DARD PROCEDURE) and remove the A/C condenser (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING/A/C CONDENSER - REMOVAL) (if A/C equipped).
(3) Remove
cooler (Refer to 7 - COOLING/TRANSMISSION/TRANS COOLER - REMOVAL).
transmission auxiliary
the
(4) Remove the boost tubes from the charge air
cooler (Fig. 24).
(1) If the engine experiences a turbocharger failure or any other situation where oil or debris get into the charge air cooler, the charge air cooler must be cleaned internally.
(2) Position the charge air cooler so the inlet and
outlet tubes are vertical.
(3) Flush the cooler internally with solvent in the
direction opposite of normal air flow.
(4) Shake the cooler and lightly tap on the end tanks with a rubber mallet to dislodge trapped debris. (5) Continue flushing until all debris or oil are
removed.
(5) Remove the charge air cooler bolts. Pivot the
(6) Rinse the cooler with hot soapy water to
charge air cooler forward and up to remove.
remove any remaining solvent.
(7) Rinse thoroughly with clean water and blow
dry with compressed air.
INSPECTION
Visually inspect the charge air cooler for cracks, holes, or damage. Inspect the tubes, fins, and welds for tears, breaks, or other damage. Replace the charge air cooler if damage is found.
Pressure test the charge air cooler, using Charge Air Cooler Tester Kit #3824556. This kit is available through Cumminst Service Products. Instructions are provided with the kit.
INSTALLATION
(1) Position the charge air cooler. Install the bolts
and tighten to 2 N·m (17 in. lbs.) torque.
(2) Install
the air intake system tubes to the charge air cooler. With the clamps in position, tighten the clamps to 11 N·m (95 in. lbs.) torque.
(3) Install
the transmission auxiliary cooler (if equipped) (Refer to 7 - COOLING/TRANSMISSION/ TRANS COOLER - INSTALLATION).
(4) Install the A/C condenser (if A/C equipped) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMB- ING/A/C CONDENSER - INSTALLATION). Recharge A/C system (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING - STANDARD PROCEDURE).
(5) Connect the battery negative cables. (6) Start engine and check for boost system leaks.
Fig.24AirIntakeSystemTubes
1 - BOLT 2 - CHARGE AIR COOLER 3 - CLAMP 4 - BOOST TUBE
CLEANING
CAUTION: Do not use caustic cleaners to clean the charge air cooler. Damage to the charge air cooler will result.
NOTE: If internal debris cannot be removed from the cooler, the charge air cooler MUST be replaced.
DR
FRAMES & BUMPERS
13 - 1
FRAMES & BUMPERS
TABLE OF CONTENTS
page
page
BUMPERS
SPECIFICATIONS - TORQUE . . . . . . . . . . . . . . . 1
FRONT AIR DAM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2FRONT BUMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2FRONT FASCIA
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3REAR BUMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4FRAME
STANDARD PROCEDURE
STANDARD PROCEDURE - LIGHT DUTY
FRONT FRAME RAIL TIP REPLACEMENT . . . . 4
STANDARD PROCEDURE - HYDROFORM
FENDER RAIL REPAIR . . . . . . . . . . . . . . . . . 12
STANDARD PROCEDURE - REAR FRAME
H-SECTION REPLACEMENT . . . . . . . . . . . . . 15
BUMPERS SPECIFICATIONS - TORQUE
SPECIFICATIONS
SPECIFICATIONS - FRAME DIMENSIONS . . . 17
. . . . . . . . . . . . 23
SPECIFICATIONS - TORQUEFRONT CROSSMEMBER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23FRONT SKID PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24TRANSMISSION CROSSMEMBER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25TRAILER HITCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25TRANSFER CASE SKID PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26FRONT TOW HOOK ASSEMBLY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26TORQUE SPECIFICATIONS
DESCRIPTION
Front bumper center bracket nuts
Front bumper stud plate nuts
License plate hitch reinforcement bolts
Rear bumper support bracket stud plate nuts Rear bumper support bracket to hitch bolts
Rear bumper to hitch bolts
N·m 95
95
54
54
54
54Ft. Lbs.
In. Lbs.
70
70
40
40
40
40— — — — — —
13 - 2
FRAMES & BUMPERS
FRONT AIR DAM REMOVAL
FRONT BUMPER REMOVAL
DR
(1) Using a trim stick C-4755 or equivalent,
remove the fog lamp trim bezels. (Fig. 1)
(2) Remove the air dam screws through the fog
lamp opening (1 per side).
(3) Remove the two outboard screws. (4) Remove the three middle screws and remove
the air dam.
Fig.1FOGLAMPBEZEL
1 - BUMPER 2 - BEZEL
INSTALLATION
(1) Position the air dam onto the bumper and seat
the carrot type fasteners fully.
(2) Starting at the center screw install the three
middle screws.
ing.
(3) Install the screws through the fog lamp open-
(4) Install the two outboard screws. (5) Position the fog lamp trim bezels into the
bumper and seat fully.
(1) Using a grease pencil or equivalent, mark the position of the bumper on the frame rail tip to aid installation.
(2) Disconnect the fog lamp electrical connector at
the left frame rail.
device.
(3) Support the bumper with a suitable lifting
(4) Remove the center bracket nuts and bolts and
remove bumper. (Fig. 2)
Fig.2BUMPERSUPPORTBRACKET-TYPICAL
1 - FASCIA - SPORT MODEL 2 - SUPPORT BRACKET 3 - FASCIA SUPPORT BRACKET 4 - WHEELHOUSE SPLASH SHIELD SUPPORT BRACKET 5 - BUMPER CENTER BRACKET 6 - NUTS (4 PER SIDE) 7 - FRAME RAIL TIP 8 - CENTER BRACKET NUTS (2 PER SIDE) 9 - CENTER BRACKET BOLTS ASSEMBLY (1 PER SIDE) 10 - FOG LAMP
INSTALLATION
(1) Install the bumper onto the frame rails and position the wheelhouse splash shield into the sup- port brackets.
(2) Install the bolts and nuts. (3) Line up the bumper with the marks made pre- viously and tighten the bolts and nuts to 95 N·m (70
ft. lbs.).(4) Check and adjust the bumper alignment as necessary. (Refer to 23 - BODY/BODY STRUCTURE/ GAP AND FLUSH - SPECIFICATIONS)
DR
FRAMES & BUMPERS
13 - 3
FRONT FASCIA REMOVAL
ST/SLT/SLT+ - FASCIA REMOVAL
(1) Remove the two screws at each trailing edge of
the fascia. (Fig. 3)
(2) Using a trim stick C-4755 or equivalent, care- fully release the six lower clips and remove the close out panel.
(3) Using a trim stick C-4755 or equivalent, care-
fully remove the step pad.
(4) Remove and discard the four push pin fasten-
ers and remove the fascia.
Fig.4SPORTFASCIA
1 - STEP PAD 2 - FASCIA (SPORT MODEL ONLY) 3 - SCREWS (3 PER SIDE) 4 - UPPER FASCIA SUPPORT BRACKET 5 - WHEELHOUSE SPLASH SHIELD BRACKET 6 - INBOARD BUMPER BRACKET ATTACHMENTS 7 - PUSH PIN FASTENERS (4) 8 - LOWER SCREWS (5)
INSTALLATION
NOTE: The left and right inboard bumper to bracket attachments must be secured before installing the fascia and step pad.
Fig.3UPPERFASCIA-ST/SLT/SLT+
ST/SLT/SLT+ FASCIA INSTALLATION
1 - STEP PAD 2 - UPPER FASCIA (ST/SLT/SLT+ MODEL ONLY) 3 - INBOARD BUMPER BRACKET ATTACHMENTS 4 - SCREWS (4) 5 - PUSH PIN FASTENERS (4)
SPORT FASCIA REMOVAL (1) Raise and support
to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)
the vehicle.
(Refer
(2) Remove the three screws at each trailing edge
of the fascia. (Fig. 4)
(3) Remove the five lower screws. (4) Remove and discard the four upper push pins. (5) Using a trim stick C-4755 or equivalent, care- fully release the six lower clips and remove the close out panel.
(6) Using a trim stick C-4755 or equivalent, care-
fully remove the step pad.
(7) Spread the fascia out at the wheels and remove
from the vehicle.
(1) Install the fascia. (2) Position the close out panel and seat the 6
lower clips fully.
(3) Install four new upper push pin fasteners. (4) Position the step pad onto the fascia and fully
seat the attachment clips.
(5) Align the fascia to the fender with a 19 mm (0.75 inch) gap and install the two screws at each trailing edge of the fascia.
SPORT FASCIA INSTALLATION
(1) Position the fascia onto the bumper. (2) Position the step pad onto the fascia and fully
seat the attachment clips.
(3) Install four new upper push pin fasteners. (4) Install the five lower screws. (5) Install the three screws at each trailing edge of
the fascia.
13 - 4
FRAMES & BUMPERS
DR
REAR BUMPER REMOVAL
(1) Raise and support
to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)
the vehicle.
(Refer
(2) Remove the license plate. (3) Remove the bolts behind the plate. (4) Disconnect the license plate light electrical con-
nectors.
(5) Disconnect the trailer light connector electrical
connection, if equipped.
(6) Remove the two bolts along the front upper
edge of the bumper near the frame tips.
(7) Support the bumper with a suitable lifting device. (8) Remove the bolts attaching the bumper support
brackets to the trailer hitch. (Fig. 5)
Fig.5TRAILERHITCH
1 - HITCH 2 - HITCH BOLTS (4) 3 - BUMPER BRACKET BOLTS (4) 4 - BUMPER SUPPORT BRACKETS
INSTALLATION
(1) Align the holes in the bumpers to the trailer
hitch pins and install the bumper.
(2) Install the support bracket to the hitch bolts,
loosely.
(3) Install the front upper edge to the trailer hitch
bolts and tighten to 54 N·m (40 ft. lbs.).
(4) Install the license plate reinforcement to hitch
bolts and tighten to 54 N·m (40 ft. lbs.).
(5) Tighten the left bumper bracket bolts to 54
N·m (40 ft. lbs.).
N·m (40 ft. lbs.).
(6) Tighten the right bumper bracket bolts to 54
(7) Connect the trailer light connector electrical
connection, if equipped.
(8) Connect the license plate light electrical con-
nectors.
(9) Install the license plate.
FRAME
STANDARD PROCEDURE
STANDARD PROCEDURE - LIGHT DUTY FRONT FRAME RAIL TIP REPLACEMENT
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE EYE PROTECTION WHEN GRIND- ING OR WELDING METAL, SERIOUS EYE INJURY CAN RESULT. † BEFORE PROCEEDING WITH FRAME REPAIR INVOLVING GRINDING OR WELDING, VERIFY THAT VEHICLE FUEL SYSTEM IS NOT LEAKING OR IN CONTACT WITH REPAIR AREA, PERSONAL INJURY CAN RESULT. † DO NOT ALLOW OPEN FLAME OR HEAT AND METAL SPATTER FROM ARC WELDING, TO CON- TACT PLASTIC BODY PANELS. FIRE OR EXPLO- SION CAN RESULT. † WHEN WELDED FRAME COMPONENTS ARE REPLACED, ENSURE COMPLETE PENETRATION WELD IS ACHIEVED DURING INSTALLATION. IF NOT, DANGEROUS OPERATING CONDITIONS CAN RESULT. † STAND CLEAR OF CABLES OR CHAINS ON PULLING EQUIPMENT DURING FRAME STRAIGHT- ENING OPERATIONS, PERSONAL INJURY CAN RESULT. † DO NOT VENTURE UNDER A HOISTED VEHI- CLE THAT IS NOT SUPPORTED ON SAFETY STANDS, PERSONAL INJURY CAN RESULT.
CAUTION: 1500 series Dodge Ram Trucks (2002 and later) are not designed for snow plow equipment. The front collision repair tips must not be installed on any truck equipped with a snow plow, or even intended to be equipped with a snow plow.
CAUTION: This procedure is designed to replace the front frame rail tips that have been damaged in the crush initiator zones. Prior to any cutting, the vehicle must be mounted on the appropriate frame repair equipment (“frame rack”), checked with three dimensional measuring equipment, and the neces- sary pull corrections made. If damage remains in the frame beyond the area covered by this service part after the pull, the frame must be replaced in its entirety.
