Heat DODGE RAM 2001 Service Repair Manual

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) Connect the exhaust pipe support hangers on
the (Fig. 8).
(2) 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.
(3) Position the exhaust pipe to manifold. Install
the bolts, retainers and nuts. Tighten the nuts to 31
N´m (23 ft. lbs.) torque.
(4) Tighten the 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.
Adjust the alignment, if needed.
EXHAUST PIPE - 5.9L DIESEL
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
bolts (Fig. 11).
(6) Remove the exhaust pipe from the transmis-
sion support (Fig. 11).
INSPECTION
Discard rusted clamps, broken or worn supports
and attaching parts. Replace a component with orig-
inal equipment parts, or equivalent. This will assure
Fig. 9 Catalytic Converter and Clamp Location 5.9L
Heavy Duty
1 - DOWN PIPE RIGHT
2 - CLAMP
3 - CLAMP
4 - HANGER ASSY. DUAL CLAMP
5 - MUFFLER
6 - EXTENSION PIPE
7 - CATALYTIC CONVERTER
8 - DOWN PIPE LEFT
Fig. 10 Catalytic Converter and Clamp Location 8.0L
1 - CLAMPS
2 - CATALYTIC CONVERTERS
3 - MUFFLER
4 - HANGER ASSY. DUAL CLAMP
5 - EXTENSION PIPES
6 - DOWN PIPE
Fig. 11 Exhaust Pipe Removal/Installation
1 - EXHAUST PIPE
2 - TURBOCHARGER EXHAUST PIPE
BR/BEEXHAUST SYSTEM 11 - 9
EXHAUST PIPE - 5.9L HEAVY DUTY/8.0L (Continued)

proper alignment with other parts in the system and
provide acceptable exhaust noise levels.
INSTALLATION
(1) Install the exhaust pipe into the transmission
support and onto the turbocharger flange (Fig. 11).
(2) Install the exhaust pipe-to-turbocharger elbow
bolts 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 fromentering 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, crossmember or bracket.
(3) Slide the shield out around the exhaust system.
INSTALLATION
(1)Position the exhaust heat shield to the floor pan,
crossmember or bracket and install the nuts or bolts.
(2)Tighten the nuts and bolts 11 N´m (100 in. lbs.).
(3) Lower the vehicle.
MUFFLER - 3.9L/5.2L/5.9L/8.0L
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 hanger (Fig. 12) (Fig.
13).
(4) Remove clamps and nuts (Fig. 12) (Fig. 13).
(5) Remove the muffler.
Fig. 12 Muffler for 3.9L, 5.2L and 5.9L-Light Duty Engines
1 - TAILPIPE
2 - CLAMP
3 - MUFFLER LIGHT DUTY
11 - 10 EXHAUST SYSTEMBR/BE
EXHAUST PIPE - 5.9L DIESEL (Continued)

INSTALLATION
(1) Assemble muffler and clamps loosely to permit
proper alignment of all parts.
(2) Connect the muffler hanger.
(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. A
minimum of 25.4 mm (1.0 in.) is required between
exhaust system components and body/frame parts.
Adjust the alignment, if needed.
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. 14).
(4) Disconnect the muffler from the hanger isola-
tors (Fig. 14).
(5) Disconnect the muffler from the tailpipe.
(6) Disconnect the muffler from the extension pipe
and remove from the vehicle..
INSTALLATION
(1) Install the muffler hanger rods into the isola-
tors (Fig. 14).(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.
TAILPIPE - 3.9L/5.2L/5.9L
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.
(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-
Fig. 13 Muffler for 5.9L Heavy Duty and 8.0L
1 - HANGER
2 - TAILPIPE
3 - CLAMP
4 - MUFFLER
5 - INSULATOR
Fig. 14 Muffler Removal/Installation
1 - HANGER BRACKETS
2 - ISOLATOR
3 - TAILPIPE
4 - CLAMP
5 - MUFFLER
6 - EXTENSION PIPE
7 - HANGER W/CLAMP
BR/BEEXHAUST SYSTEM 11 - 11
MUFFLER - 3.9L/5.2L/5.9L/8.0L (Continued)

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.
(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.
TAILPIPE - 5.9L HEAVY
DUTY/8.0L
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the clamp nuts with MopartRust
Penetrant. Allow 5 minutes for penetration.
(3) Disconnect the exhaust tailpipe support hang-
ers (Fig. 15).
(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 (Fig. 15).
(2) Connect the support hangers (Fig. 15).
(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.
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. 16).
(5) Remove the muffler-to-tailpipe clamps (Fig. 16).
(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. 16)
(3) Install the exhaust clamp, align the exhaust
system, and tighten the clamp 48 N´m (35 ft. lbs.)
torque.
(4) Lower the vehicle.
(5) Connect the battery negative cables.
Fig. 15 TAILPIPE 8.0L AND 5.9L HEAVY DUTY
1 - HANGER
2 - TAILPIPE
3 - CLAMP
4 - MUFFLER
5 - INSULATOR
11 - 12 EXHAUST SYSTEMBR/BE
TAILPIPE - 3.9L/5.2L/5.9L (Continued)

(6) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
RESONATOR
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Remove the exhaust clamps from the resonator
to extension pipes (Fig. 17).
(4) Separate the resonator from the front and rear
extension pipes (Fig. 17) and remove the resonator
from the vehicle.
INSTALLATION
(1) Assemble the resonator to the front and rear
extension pipes (Fig. 17).
(2) Install new exhaust clamps, align the exhaust
system, and tighten the exhaust clamps to 48 N´m
(35 ft. lbs.) torque.
(3) Lower the vehicle.
(4) Connect the battery negative cables.
(5) Start the engine and inspect for exhaust leaks.
TURBOCHARGER
DESCRIPTION
The turbocharger is an exhaust-driven super-
charger 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 cylinders, which creates more power during com-
bustion.
The turbocharger assembly consists of four (4)
major component systems (Fig. 18) (Fig. 19):
²Turbine section
²Compressor section
²Bearing housing
²Wastegate
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:
²Improved engine performance
²Lower exhaust smoke density
²Improved operating economy
²Altitude compensation
²Noise reduction.
Fig. 16 Tailpipe Removal/Installation
1 - HANGER BRACKETS
2 - ISOLATOR
3 - TAILPIPE
4 - MUFFLER
Fig. 17 Resonator Removal/Installation
1 - EXTENSION PIPE
2 - RESONATOR
3 - EXTENSION PIPE
4 - CLAMP
BR/BEEXHAUST SYSTEM 11 - 13
TAILPIPE - 5.9L DIESEL (Continued)

bearing housing, routes the engine oil back to the
crankcase.
The most common turbocharger failure is bearing
failure related to repeated hot shutdowns with inad-
equate ªcool-downº periods. A sudden engine shut
down after prolonged operation will result in the
transfer of heat from the turbine section of the tur-
bocharger to the bearing housing. This causes the oil
to overheat and break down, which causes bearing
and shaft damage 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.
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Disconnect the exhaust pipe from the turbo-
charger elbow (Fig. 22).
(4) Lower vehicle.
(5) Disconnect the turbocharger air inlet hose (Fig.
23).
(6) Disconnect the turbocharger oil supply line and
the oil drain tube from the turbocharger (Fig. 24).
(7) Disconnect the charge air cooler inlet pipe from
the turbocharger (Fig. 24).(8) Remove the turbocharger and gasket from the
exhaust manifold.
(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 dis-
charge elbow and clamp to the new assembly.
(11) Clean and inspect the sealing surface.
Fig. 21 Turbocharger Oil Supply and Drain
1 - BEARINGS
2 - OIL SUPPLY (FROM FILTER HEAD)
3 - OIL RETURN (TO SUMP)
Fig. 22 Exhaust Pipe Removal/Installation
1 - EXHAUST PIPE
2 - TURBOCHARGER EXHAUST PIPE
Fig. 23 Turbocharger Air Inlet Hose
1 - AIR FILTER HOUSING COVER
2 - TURBOCHARGER
3 - AIR INLET TUBE
4 - HOSE CLAMP
5 - HINGE TABS
6 - FILTER MINDER
7 - CLIPS (4)
8 - TUBE ALIGNMENT NOTCHES
BR/BEEXHAUST SYSTEM 11 - 15
TURBOCHARGER (Continued)

(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 fitting
nut to 20 N´m (133 in. 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. 23). Tighten the clamp to 11 N´m (95 in. lbs.)
torque.
(7) Raise vehicle on hoist.
(8) Connect the exhaust pipe to the turbocharger
(Fig. 22) 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. 28) 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.
OPERATION
Intake air is drawn through the air cleaner and
into the turbocharger compressor housing. Pressur-
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.
REMOVAL
WARNING: IF THE ENGINE WAS JUST TURNED
OFF, THE AIR INTAKE SYSTEM TUBES MAY BE
HOT.
(1) Disconnect the battery negative cables.
(2) Remove the front bumper (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT
BUMPER - REMOVAL).
Fig. 26 Measure Turbocharger Axial End Play
Fig. 27 Measure Turbocharger Bearing Radial
Clearance
1 - FEELER GAUGE
Fig. 28 Intake Air Circulation
1 - CHARGE AIR COOLER
2 - AIRFILTER
3 - TURBOCHARGER
BR/BEEXHAUST SYSTEM 11 - 17
TURBOCHARGER (Continued)

(3) Remove the front support bracket.
(4) 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) (Fig.
29) (if A/C equipped) .
(5) Remove the transmission auxiliary cooler (Fig.
29) (Refer to 7 - COOLING/TRANSMISSION/TRANS
COOLER - REMOVAL).
(6) Remove the boost tubes from the charge air
cooler (Fig. 30).
(7) Remove the charge air cooler bolts. Pivot the
charge air cooler forward and up to remove.
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.
(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.
(6) Rinse the cooler with hot soapy water to
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 CumminstService 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.
Fig. 29 Condenser and Transmission Auxiliary
Cooler
1 - A/C CONDENSOR
2 - TRANSMISSION COOLER
3 - INTERCOOLER
Fig. 30 Air Intake System Tubes
1 - CLAMP
2 - INTERCOOLER INLET DUCT
3 - CLAMP
4 - VALVE COVER
5 - AIR INLET HOUSING
6 - CLAMP
7 - INTERCOOLER OUTLET DUCT
8 - CLAMP
9 - INTERCOOLER
11 - 18 EXHAUST SYSTEMBR/BE
CHARGE AIR COOLER AND PLUMBING (Continued)

(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/
PLUMBING/A/C CONDENSER - INSTALLATION).
Recharge A/C system (Refer to 24 - HEATING & AIRCONDITIONING/PLUMBING - STANDARD PRO-
CEDURE).
(5) Install the front support bracket. Install and
tighten the bolts.
(6) Install the front bumper (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT
BUMPER - INSTALLATION).
(7) Connect the battery negative cables.
(8) Start engine and check for boost system leaks.
BR/BEEXHAUST SYSTEM 11 - 19
CHARGE AIR COOLER AND PLUMBING (Continued)

CAUTION: Do not reuse damaged fasteners, quality
of repair would be suspect. Do not drill holes in top
or bottom frame rail flanges, frame rail failure can
result. Do Not use softer than Grade 5 bolts to
replace production fasteners, loosening or failure
can result. When using heat to straighten frame
components do not exceed 566ÉC (1050ÉF), metal
fatigue can result. Welding the joints around riveted
cross members and frame side rails can weaken
frame.
FRAME STRAIGHTENING
When necessary, a conventional frame that is bent
or twisted can be straightened by application of heat.
The temperature must not exceed 566ÉC (1050ÉF).
The metal will have a dull red glow at the desired
temperature. Excessive heat will decrease the
strength of the metal and result in a weakened
frame.
Welding the joints around riveted cross members
and frame side rails is not recommended.
A straightening repair process should be limited to
frame members that are not severely damaged. The
replacement bolts, nuts and rivets that are used to
join the frame members should conform to the same
specifications as the original bolts, nuts and rivets.
FRAME REPAIRS
DRILLING HOLES
Do not drill holes in frame side rail top and bottom
flanges, metal fatigue can result causing frame fail-
ure. Holes drilled in the side of the frame rail must
be at least 38 mm (1.5 in.) from the top and bottom
flanges.
Additional drill holes should be located away from
existing holes.
WELDING
Use MIG, TIG or arc welding equipment to repair
welded frame components.
Frame components that have been damaged should
be inspected for cracks before returning the vehicle
to use. If cracks are found in accessible frame com-
ponents perform the following procedures.
(1) Drill a hole at each end of the crack with a 3
mm (O.125 in.) diameter drill bit.
(2) Using a suitable die grinder with 3 inch cut off
wheel, V-groove the crack to allow 100% weld pene-
tration.
(3) Weld the crack.(4) If necessary when a side rail is repaired, grind
the weld smooth and install a reinforcement channel
(Fig. 9) over the repaired area.
NOTE: If a reinforcement channel is required, the
top and bottom flanges should be 0.250 inches nar-
rower than the side rail flanges. Weld only in the
areas indicated (Fig. 9).
FRAME FASTENERS
Bolts, nuts and rivets can be used to repair frames
or to install a reinforcement section on the frame.
Bolts can be used in place of rivets. When replacing
rivets with bolts, install the next larger size diameter
bolt to assure proper fit. If necessary, ream the hole
out just enough to sufficiently receive the bolt.
Conical-type washers are preferred over the split-
ring type lock washers. Normally, grade-5 bolts are
adequate for frame repair.Grade-3 bolts or softer
should not be used.Tightening bolts/nuts with the
correct torque, refer to the Introduction Group at the
front of this manual for tightening information.
SPECIFICATIONS
FRAME DIMENSION
Frame dimensions are listed in Millimeters (mm)
scale. All dimensions are from center to center of
Principal Locating Point (PLP), or from center to cen-
ter of PLP and fastener location (Fig. 10).
Fig. 9 Frame Reinforcement
1 - .250 IN FROM EDGE
2 - TOP FLANGE
3 - BOTTOM FLANGE
4 - FRAME RAIL
5 - FRAME REPAIR REINFORCEMENT
BR/BEFRAME & BUMPERS 13 - 7
FRAME (Continued)