battery DODGE RAM 2001 Service Repair Manual

(5) Using two (2) new gaskets, install the intake
air grid heater and air inlet housing (Fig. 168). Posi-
tion the ground cable and install and tighten the
bolts to 24 N´m (18 ft. lbs.) torque.
(6) Install and tighten the air intake heater power
supply nuts to 14 N´m (120 in. lbs.) torque.
(7) Install the engine oil dipstick tube and mount-
ing bolt (Fig. 167).
(8) Position the charge air cooler outlet tube onto
the air inlet housing (Fig. 167). Tighten the clamps
to 8 N´m (72 in. lbs.) torque.
(9) Perform the fuel system air bleed procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(10) Connect the battery negative cables.
EXHAUST MANIFOLD
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Disconnect the exhaust pipe from the turbo-
charger elbow (Fig. 170).
(4) Lower vehicle.
(5) Disconnect the turbocharger air inlet hose (Fig.
171).
(6) Disconnect the turbocharger oil supply line and
the oil drain tube from the turbocharger (Fig. 172).
(7) Disconnect the charge air cooler inlet pipe from
the turbocharger (Fig. 172).
(8) Remove the turbocharger and gasket from the
exhaust manifold.
(9) Remove the cab heater return pipe nut from
the exhaust manifold stud. Position the tube out of
the way.
Fig. 170 Exhaust Pipe
1 - EXHAUST PIPE
2 - TURBOCHARGER EXHAUST PIPE
Fig. 171 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
Fig. 172 Oil Supply Line and Charge Air Cooler Inlet
Duct
1 - EXHAUST PIPE
2 - TURBOCHARGER
3 - AIR INLET TUBE
4 - INTERCOOLER INLET DUCT
5 - WASTE GATE ACTUATOR
BR/BEENGINE 5.9L DIESEL 9 - 303
INTAKE MANIFOLD (Continued)

(10) Remove the exhaust manifold-to-cylinder head
bolts and spacers (Fig. 173).
(11) Remove the exhaust manifold and gaskets
(Fig. 173).
CLEANING
Clean the cylinder head and exhaust manifold seal-
ing surfaces with a suitable scraper. Use a Scotch-
BriteŸ pad or equivalent.
INSPECTION
Inspect the exhaust manifold for cracks. Measure
the exhaust manifold for flatness. Place a ruler over
all of the exhaust ports and insert a feeler gauge
between the port flange and the ruler.
INSTALLATION
(1) Using new gaskets, install the exhaust mani-
fold and gaskets. Install the bolts and spacers and
tighten the bolts in the sequence shown in (Fig. 173)
to 43 N´m (32 ft. lbs.) torque.
(2) Install the cab heater return hose to the man-
ifold bolt stud. Tighten the nut to 24 N´m (18 ft. lbs.)
torque.
(3) Install the turbocharger. Apply anti-seize to the
studs and then tighten the turbocharger mounting
nuts to 32 N´m (24 ft. lbs.) torque.(4) Install the oil drain tube and oil supply line to
the turbocharger. Tighten the drain tube bolts to 24
N´m (18 ft. lbs.) torque.
(5)Pre-lube the turbocharger.Pour 50 to 60 cc
(2 to 3 oz.) clean engine oil in the oil supply line fit-
ting. Rotate the turbocharger impeller by hand to
distrubute the oil thoroughly.
(6) Install and tighten the oil supply line fitting
nut to 20 N´m (133 in. lbs.) torque.
(7) Position the charge air cooler inlet pipe to the
turbocharger. With the clamp in position, tighten the
clamp nut to 8 N´m (72 in. lbs.) torque.
(8) Position the air inlet hose to the turbocharger
(Fig. 171). Tighten the clamp to 8 N´m (72 in. lbs.)
torque.
(9) Raise vehicle on hoist.
(10) Connect the exhaust pipe to the turbocharger
(Fig. 170) and tighten the bolts to 34 N´m (25 ft. lbs.)
torque.
(11) Lower the vehicle.
(12) Connect the battery negative cables.
(13) Start the engine to check for leaks.
GEAR HOUSING
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Remove the oil pan and suction tube (Refer to 9
- ENGINE/LUBRICATION/OIL PAN - REMOVAL).
(4) Partially drain engine coolant into container
suitable for re-use (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(5) Lower vehicle.
(6) Remove radiator upper hose.
(7) Disconnect coolant recovery bottle hose from
radiator filler neck and lift bottle off of fan shroud.
(8) Disconnect windshield washer pump supply
hose and electrical connections and lift washer bottle
off of fan shroud.
(9) Remove the fan shroud-to-radiator mounting
bolts.
(10) Remove viscous fan/drive assembly (Refer to 7
- COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(11) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(12) Remove the cooling fan support/hub from the
front of the engine (Fig. 174).
(13) Raise the vehicle on hoist.
(14) Remove the crankshaft damper (Fig. 175)
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(15) Lower the vehicle.
Fig. 173 Exhaust Manifold and Gaskets
9 - 304 ENGINE 5.9L DIESELBR/BE
EXHAUST MANIFOLD (Continued)

(3) Install the injection pump (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL INJECTION
PUMP - INSTALLATION).
(4) Install the camshaft (Refer to 9 - ENGINE/EN-
GINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - INSTALLATION). Align the crankshaft,
camshaft, and injection pump gear marks as shown
in (Fig. 178).
(5) If a new housing is installed, the camshaft
position sensor must be transferred to the new hous-
ing.
(6) Obtain a seal pilot/installation tool from a
crankshaft front seal service kit and install the pilot
into the crankshaft front oil seal.
(7) Apply a bead of MopartSilicone Rubber Adhe-
sive Sealant or equivalent to the gear housing cover.
Be sure to surround all through holes.
(8) Using the seal pilot to align the cover (Fig.
179), install the cover to the housing and install the
bolts. Tighten the bolts to 24 N´m (18 ft. lbs.) torque.
(9) Remove the seal pilot.
(10) Raise the vehicle.
(11) Trim any excess gear housing gasket to make
it flush with the oil pan rail.
(12) Using a new gasket, install the oil pan and
suction tube (Refer to 9 - ENGINE/LUBRICATION/
OIL PAN - INSTALLATION).
(13) Install the crankshaft damper (Fig. 175)
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).
(14) Lower vehicle.
(15) Install the fan support/hub assembly (Fig.
174) and tighten bolts to 24 N´m (18 ft. lbs.) torque.(16) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(17) Install the cooling fan and shroud together
(Refer to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
(18) Install the windshield washer reservoir to the
fan shroud and connect the washer pump supply
hose and electrical connection.
(19) Install the coolant recovery bottle to the fan
shroud and connect the hose to the radiator filler
neck.
(20) Install the radiator upper hose and clamps.
(21) Add engine oil.
(22) Add coolant (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(23) Connect the battery cables.
(24) Start engine and inspect for leaks.
GEAR HOUSING COVER
REMOVAL
(1) Disconnect both battery negative cables.
(2) Raise vehicle on hoist.
(3) Partially drain engine coolant into container
suitable for re-use (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(4) Lower vehicle.
(5) Remove radiator upper hose.
(6) Disconnect coolant recovery bottle hose from
radiator filler neck and lift bottle off of fan shroud.
(7) Disconnect windshield washer pump supply
hose and electrical connections and lift washer bottle
off of fan shroud.
(8) Remove viscous fan/drive assembly (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
Fig. 178 Camshaft/Crankshaft Gear Alignment
Fig. 179 Installing Cover with Seal Pilot
1 - SEAL PILOT
9 - 306 ENGINE 5.9L DIESELBR/BE
GEAR HOUSING (Continued)

(8) Install the fan support/hub assy. (Fig. 180) and
tighten bolts to 24 N´m (18 ft. lbs.) torque.
(9) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(10) Install the cooling fan and shroud together
(Refer to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
(11) Install the windshield washer reservoir to the
fan shroud and connect the washer pump supply
hose and electrical connection.(12) Install the coolant recovery bottle to the fan
shroud and connect the hose to the radiator filler
neck.
(13) Install the radiator upper hose and clamps.
(14) Add coolant (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(15) Connect the battery cables.
(16) Start engine and inspect for leaks.
9 - 308 ENGINE 5.9L DIESELBR/BE
GEAR HOUSING COVER (Continued)

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)