OEM 2004 Dodge Ram 2500 Exhaust Manifold

2004 Dodge Ram 2500 Exhaust Manifold Parts and Q&A

• Q: How to Service and Repair an Exhaust Manifold on 2004 Dodge Ram 2500?

  A: When working on the exhaust manifold, first turn off the negative battery cables and lift the vehicle on a hoist. Remove the exhaust pipe from the turbocharger elbow, then set the vehicle down and take out the turbocharger air inlet hose. Toss out the air cleaner assembly and then unplug the turbocharger oil supply line and oil drain tube, plus the charge air cooler inlet pipe from the turbo. Take out the turbine and gasket from the exhaust manifold and then get rid of the nuts holding the return pipe pipe to the exhaust stud. Lastly, place the tube so it isn't in your way. Unfasten the heat shield, bolt lockplates from the exhaust manifold and cylinder head bolts and spacers, then pull out the exhaust manifold and its gaskets. Cracks and dirt from the spaces around the cylinder head and the exhaust manifold should be cleaned using a scraper and Scotch-Brite or another kind of disc pad. Search for cracks in the exhaust manifold and be certain its flatness has no more than 0.20 mm (0.008 in.) of maximum variation. Use updated gaskets to install the exhaust manifold and the gaskets and then assemble the bolts and spacers, tightening everything to 43 Nm (32 ft. lbs.) using the proper order. After tightening the four center bolts and setting the heat shield, tighten the other bolts to 24 Nm (18 ft. lbs.) and add the cab heater tube and exhaust manifold bolt retention straps. Set the cab heater return hose on the manifold bolt stud and tighten the nut to 24 Nm (18 ft. lbs.) torque. Replace the old gasket, slather anti-seize on the studs and tighten the turbocharger mounting nuts to 43 Nm (32 ft. lbs.). Put the oil drain tube with a new gasket on the turbocharger and attach it with the bolts tightened to 24 Nm (18 ft. lbs.). Pour oil into the turbocharger's supply line until it reaches the 2 - 3 oz. mark, then use your hand to rotate the impeller until the oil has been spread through the turbo. Turn the oil supply line fitting nut to 24 Nm (18 ft. lbs.) while tightening and set the charge air cooler inlet pipe over the turbocharger, then tighten the hose clamp with 8 Nm (72 in. lbs.) torque. Fit the air inlet hose to the turbocharger and clinch the clamp to 8 Nm (72 in. lbs.) tightness. Lift the car on the hoist, attach the exhaust pipe to the turbocharger and tighten all the bolts to 25 ft. lbs. torque. Set the car low, reattach the negative battery cables and power on the engine to see if there are leaks.