RAM 2500 Truck 2WD V8-5.7L VIN D (2004)
Exhaust Manifold: Service and Repair
EXHAUST MANIFOLD
REMOVAL
1. Disconnect negative battery cable.
2. Raise vehicle.
3. Remove exhaust pipe to manifold bolts.
4. Lower vehicle.
5. Install engine support fixture special tool # 8534.
6. Raise engine enough to remove manifolds.
CAUTION: Do not damage engine harness while raising the engine.
7. Remove heat shield.
8. Remove manifold bolts.
9. Remove manifold and gasket.
CLEANING
Clean mating surfaces on cylinder head and manifold. Wash with solvent and blow dry with compressed 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. Install manifold gasket and manifold.
2. Install manifold bolts and tighten to 25 Nm (18 ft. lbs.).
3. Install heat shield and tighten nuts to 15 Nm (11 ft. lbs.).
4. Lower engine.
CAUTION: Do not damage engine harness while lowering the engine.
5. Remove engine support fixture from engine.
6. Raise vehicle.
7. Tighten right and left side engine mount through bolts.
8. Install exhaust flange to pipe bolts.
9. Lower vehicle.
10. Connect negative battery cable.
