This procedure covers the removal and installation of the exhaust manifold on a 2014 Ram 2500 with the 6.7L Cummins diesel engine, including EGR system disconnection and heat shield removal.

Warnings

Tools required

Parts

• Exhaust manifold gasket × 1 — Use OEM specification
• EGR tube gasket/seal × 1 — Use OEM specification
• Exhaust manifold bolts/studs (if damaged) × 1 — Use OEM specification
• Heat shield gasket (if equipped) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake. Chock rear wheels securely.
2. Disconnect both negative battery cables and isolate terminals to prevent electrical issues.
3. Allow engine and exhaust system to cool completely (minimum 2 hours).
4. Apply penetrating oil to all exhaust manifold fasteners, oxygen sensor threads, and EGR tube connections. Allow to soak while proceeding with other steps.
5. Raise and support front of vehicle on jack stands if improved access is needed from below.
6. Remove engine cover if equipped by releasing retaining clips.

Procedure

1. 1

   Remove oxygen sensor(s)
   Disconnect the oxygen sensor electrical connector(s). Using an oxygen sensor socket or 22mm wrench, carefully remove the oxygen sensor(s) from the exhaust manifold. If sensor is stuck, apply heat carefully with a propane torch to the manifold boss area (not the sensor). Thread chaser may be needed for cleaning threads after removal.
   Torque spec

   O2 Sensor47 Nm (35 lb-ft)
2. 2

   Disconnect EGR system
   Locate the EGR tube connection at the exhaust manifold. Remove any brackets or support clips securing the EGR tube. Using appropriate wrenches, loosen the EGR tube fitting at the manifold connection. Carefully disconnect the tube and move aside. Cap or plug openings to prevent debris entry.
   ⚠EGR tube fittings can be brittle. Use two wrenches (one to hold, one to turn) to prevent twisting and breaking the tube.
   Torque spec

   EGR Tube Fitting47 Nm (35 lb-ft)
3. 3

   Remove heat shield
   If equipped with exhaust manifold heat shields, remove the retaining bolts securing the shield(s) to the manifold. Carefully remove heat shield and set aside. Inspect shield for damage or excessive corrosion.
   Torque spec

   Heat Shield Bolts14 Nm (10 lb-ft)
4. 4

   Disconnect exhaust downpipe
   From underneath the vehicle, locate the exhaust flange connection between the manifold outlet and the downpipe/turbocharger connection. Remove the flange bolts securing the connection. Support the exhaust pipe to prevent it from dropping. Separate the flange connection and move downpipe aside. Remove and discard old gasket.
   ⚠Support exhaust system with jack stand or wire to prevent strain on downstream hangers and components.
   Torque spec

   Flange Bolts64 Nm (47 lb-ft)
5. 5

   Remove exhaust hanger supports (if applicable)
   If the exhaust manifold has any bracket supports or hangers connecting to the engine block or transmission, remove the retaining bolts. Label or photograph connections for proper reinstallation.
   Torque spec

   Hanger Bolts27 Nm (20 lb-ft)
6. 6

   Remove exhaust manifold fasteners
   Beginning from the outer bolts/nuts and working toward the center, carefully loosen and remove all exhaust manifold mounting fasteners. Note whether your manifold uses bolts or studs with nuts - torque specifications differ. If any fasteners break or strip, stop and use proper extraction methods. Keep fasteners organized for inspection.
   ⚠Loosen fasteners gradually in a cross pattern to prevent warping the manifold. If a bolt begins to bind or twist, stop immediately and apply more penetrating oil.
   Torque spec

   Exhaust Manifold Bolts43 Nm (32 lb-ft)

   Exhaust Manifold Nuts34 Nm (25 lb-ft)
7. 7

   Remove exhaust manifold
   With all fasteners removed, carefully separate the exhaust manifold from the cylinder head. The manifold may be stuck due to carbon buildup. Gently use a pry bar at designated pry points if needed - do not pry against machined sealing surfaces. Have an assistant help support the weight of the manifold as it is heavy and awkward. Remove and discard old manifold gasket.
   ⚠️Exhaust manifold weighs approximately 40-50 lbs. Use proper lifting technique and have assistance to prevent dropping or personal injury.
8. 8

   Clean mating surfaces
   Thoroughly clean the cylinder head exhaust port mating surface using a gasket scraper and wire brush. Remove all old gasket material, carbon deposits, and debris. Do not gouge or scratch the sealing surface. Clean the manifold mating surface as well if reusing the original manifold. Wipe surfaces clean with solvent and lint-free cloth. Inspect cylinder head surface for damage, warping, or cracks.
   ℹ️Cover exposed exhaust ports with clean shop towels to prevent debris from entering the cylinders during cleaning.
9. 9

   Inspect and prepare manifold
   Inspect the exhaust manifold thoroughly for cracks, especially around bolt holes and between ports. Check manifold flatness with a straightedge - warpage exceeding 0.006 inches requires replacement or machining. If reusing manifold, ensure all threaded holes are clean and undamaged. Apply anti-seize compound to bolt threads or stud threads as specified.
   ℹ️Cummins diesel manifolds are prone to cracking. Magnetic particle or dye penetrant inspection is recommended on high-mileage engines.
10. 10

    Install new manifold gasket
    Position the new exhaust manifold gasket onto the cylinder head, aligning all bolt holes and exhaust ports. Ensure the gasket is oriented correctly per manufacturer markings (some gaskets are marked 'TOP' or 'FRONT'). The gasket should sit flat without forcing.
    ℹ️Do not use any sealant on the manifold gasket unless specifically required by gasket manufacturer. Most modern gaskets are designed to seal without additional sealant.
11. 11

    Install exhaust manifold
    With assistance, carefully position the exhaust manifold onto the cylinder head, aligning all bolt holes with the gasket and head. Start all manifold fasteners by hand to ensure proper thread engagement. Do not tighten any fasteners until all are started. Apply anti-seize compound to fastener threads as specified in torque specifications.
    Torque spec

    Exhaust Manifold Bolts43 Nm (32 lb-ft)

    Exhaust Manifold Nuts34 Nm (25 lb-ft)
12. 12

    Torque manifold fasteners
    Using a torque wrench, tighten the exhaust manifold fasteners in a center-outward pattern to the specified torque. Start with the center fasteners and work toward the outer ends in multiple passes: first to 50% torque, then to 75% torque, and finally to full specification. This ensures even gasket compression and prevents warping.
    ⚠Use the correct torque specification for your fastener type - bolts and nuts have different values. Tightening sequence center-outward is critical to prevent gasket leaks and manifold warping.
    Torque spec

    Exhaust Manifold Bolts43 Nm (32 lb-ft)

    Exhaust Manifold Nuts34 Nm (25 lb-ft)
13. 13

    Reconnect exhaust downpipe
    Position new exhaust flange gasket at the manifold outlet connection. Align the exhaust downpipe to the manifold flange. Install flange bolts with anti-seize compound applied to threads. Torque to specification in a cross pattern. Ensure exhaust system hangs properly without strain.
    Torque spec

    Flange Bolts64 Nm (47 lb-ft)
14. 14

    Reinstall heat shield and supports
    If equipped, position the heat shield over the manifold. Install and torque heat shield bolts to specification. Reinstall any exhaust hanger support brackets removed earlier and torque fasteners to specification.
    Torque spec

    Heat Shield Bolts14 Nm (10 lb-ft)

    Hanger Bolts27 Nm (20 lb-ft)
15. 15

    Reconnect EGR system
    Install new EGR tube gasket/seal at the manifold connection. Carefully position the EGR tube to the manifold fitting, ensuring proper alignment to prevent cross-threading. Hand-tighten the fitting, then torque to specification using two wrenches. Reinstall any EGR tube support brackets.
    Torque spec

    EGR Tube Fitting47 Nm (35 lb-ft)
16. 16

    Install oxygen sensor(s)
    Apply anti-seize compound to the oxygen sensor threads (avoid getting compound on the sensor tip). Thread the oxygen sensor(s) into the exhaust manifold by hand to prevent cross-threading. Torque to specification using oxygen sensor socket. Reconnect electrical connector(s) and ensure wiring is properly routed away from hot exhaust components.
    Torque spec

    O2 Sensor47 Nm (35 lb-ft)

Reassembly

1. Reinstall engine cover if it was removed.
2. Remove jack stands and lower vehicle to ground if it was raised.
3. Reconnect both negative battery cables.
4. Double-check that all fasteners have been tightened to specification and all electrical connections are secure.

Verification

• Start the engine and allow it to idle. Listen for any exhaust leaks at the manifold gasket, flange connections, and oxygen sensor ports.
• Inspect all connections visually for signs of exhaust gas leakage (soot, smoke, or hissing sounds).
• Check for proper EGR system operation - no check engine lights related to EGR or oxygen sensor codes should be present.
• After engine reaches operating temperature, re-inspect all connections for leaks. Some gaskets may seat fully only after heat cycling.
• Perform a test drive and monitor engine performance, exhaust sound, and check for any unusual odors or smoke.
• After 50-100 miles of operation, re-check manifold fastener torque as heat cycling may cause slight settling. Re-torque if necessary following center-outward pattern.

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