FLANGE NUTS

Figure 14 – SCR Catalyst Assembly

SCR CATALYST
ISOLATOR

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Page 13

Service Procedure (Continued)
23. Use the following procedure to transfer the Particulate Matter (PM) sensor with
module from the original SCR catalyst to the NEW SCR catalyst (Figure 15).
NOTE: DO NOT use a torch as a heat source.
a. Use a six sided crowfoot wrench to remove the PM sensor from the SCR
catalyst
b. If the PM sensor fails to loosen, use a torque wrench set to 118 ft. lbs.
(160 N·m) and loosen the PM sensor.
c. If the PM sensor is still not loose after applying 118 ft. lbs. (160 N·m), then
use a heat gun to heat the PM sensor boss for 1 minute at 842° F (450° C).
d. Install the PM sensor into the NEW SCR catalyst and tighten to 44 ft. lbs.
(60 N·m).

24. Use the following procedure to transfer the NOx sensor with module from the
original SCR catalyst to the NEW SCR catalyst (Figure 15).
NOTE: DO NOT use a torch as a heat source.
a. Use a six sided crowfoot wrench to remove the NOx sensor from the SCR
catalyst
b. If the NOx sensor fails to loosen, use a torque wrench set to 118 ft. lbs.
(160 N·m) and loosen the PM sensor.
c. If the NOx sensor is still not loose after applying 118 ft. lbs. (160 N·m), then
use a heat gun to heat the PM sensor boss for 1 minute at 842° F (450° C).
d. Install the NOx sensor into the NEW SCR catalyst and tighten to 41 ft. lbs.
(55 N·m).

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Service Procedure (Continued)
25. Use the following procedure to transfer the exhaust gas temperature sensor
from the original SCR catalyst to the NEW SCR catalyst (Figure 15).
CAUTION: The exhaust gas temperature sensor requires care when
removing, handling and installing. The exhaust gas temperature sensor is
sensitive to knocks and bending. Do NOT drop the sensor. Failure to
follow these instructions may result in damage to the exhaust gas
temperature sensor.
a. Use a six sided crowfoot wrench to remove the exhaust gas temperature
sensor from the SCR catalyst.
b. Install the exhaust gas temperature sensor into the NEW SCR catalyst and
tighten to 35 ft. lbs. (47 N·m).

NOX SENSOR

PM SENSOR

SCR CATALYST

TEMPERATURE SENSOR

DEF INJECTOR

Figure 15 – Selective Catalytic Reduction (SCR) Catalyst Assembly

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Service Procedure (Continued)
26. Use the following procedure to transfer the DEF injector from the original SCR
catalyst to the NEW SCR catalyst (Figure 15).

a. Loosen the DEF injector
clamp and remove the DEF
injector from the SCR catalyst
(Figure 16).

b. Inspect the opening of the
DEF injector and make sure it
is NOT plugged or restricted
with buildup of DEF crystals.
If the DEF injector opening is
plugged or restricted, clean as
necessary (Figure 17).
NOTE: Hot water may be
used to dissolve DEF crystal
buildup if the DEF injector
requires cleaning.

DEF INJECTOR CLAMP

DEF INJECTOR

Figure 16 – DEF Injector
DEF INJECTOR

c. Remove and discard the DEF
injector gasket then install a
NEW DEF injector gasket
(Figure 17).

d. Install the DEF injector onto
the SCR catalyst. Tighten the
clamp to 44 in. lbs. (5 N·m)
(Figure 16).
DEF CRYSTAL
BUILDUP

DEF INJECTOR GASKET

Figure 17 – DEF Injector Gasket

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Service Procedure (Continued)
27. Remove and discard the used
SCR
catalyst
gasket
(Figure 18).

PARTICULATE
FILTER FLANGE

28. Clean the particulate filter
flange gasket sealing surface
(Figure 18).
29. Install a NEW SCR catalyst
gasket (Figure 18).
30. Position the NEW SCR catalyst
onto the particulate filter flange
and install the three flange nuts
finger tight (Figure 14).

SCR CATALYST
GASKET

Figure 18 – SCR Catalyst Gasket

31. Install the isolator onto the SCR
catalyst hanger rod (Figure 14).
32. Tighten the SCR catalyst flange nuts to 24 ft. lbs. (32 N·m) (Figure 14).
NOTE: Assistance with exhaust system component installation is
recommended.
33. Install the tailpipe and resonator assembly to the SCR catalyst (Figure 13).
34. Install the isolators and ground strap onto the tailpipe and resonator assembly
hanger rods (Figure 13).
35. Check the exhaust system for proper alignment and for any contact with other
vehicle components. A minimum of 1.0 in. (25 mm) is required between the
exhaust system and other vehicle components. Make adjustments, if needed to
achieve proper exhaust system clearance and alignment.
36. Align the tailpipe clamp and tighten to 46 ft. lbs. (62 N·m) (Figure 13).

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Service Procedure (Continued)
37. Route the PM sensor module and NOx sensor module over to the module
mounting bracket and secure the wire harness with the three wire harness
retainers (Figure 11).

38. Install the PM sensor module to the module mounting bracket and then install
the two nuts that secure the module to the bracket. Tighten the nuts to 71 in. lbs.
(8 N·m) (Figure 10).

39. Connect the vehicle wire harness connector to the PM sensor (Figure 10).

40. Install the module mounting bracket to the vehicle frame and then install the
two nuts that secure the bracket to the frame. Tighten the nuts to 8 ft. lbs.
(11 N·m) (Figure 9).

41. Install the NOx module to the module mounting bracket (Figure 9).

42. Connect the vehicle wire harness connector to the NOx module (Figure 9).

43. Install the NOx module cover and then install the two nuts that secure the
cover. Tighten the nuts to 71 in. lbs. (8 N·m) (Figure 8).

44. Install the rear propshaft heat shield and then install the four fasteners that
secure the heat shield to the vehicle underbody (Figure 7).

45. Connect the DEF supply line to the DEF injector (Figure 6).

46. Install the heat shielding cover over the DEF supply line fitting (Figure 6).

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Service Procedure (Continued)
47. Connect the wire harness connector to the DEF injector (Figure 5).
48. Connect the green exhaust temperature sensor wire harness connector located
between the exhaust particulate filter and the transmission (Figure 4).
49. If equipped with a transfer case skid plate, install the skid plate and fasteners.
50. If equipped with a transmission closeout panel, install the panel and fasteners
(Figure 2).
NOTE: If equipped with a transmission skid plate, installation process is
similar.
51. If equipped with an underbody splash shield, install the panel and fasteners
(Figure 1).
NOTE: If equipped with a underbody skid plate, installation process is
similar.
52. Remove support and lower the vehicle.
53. Connect the negative battery cable to the negative battery post.
54. Use the following procedure to perform the SCR catalyst reset:
a. Connect the wiTECH scan tool and start a session.
b. From the “PCM View” screen, click on the “Miscellaneous Functions” tab.
c. Perform the SCR System Catalyst Reset function.
d. Using the wiTECH scan tool, clear all Diagnostic Trouble Codes (DTCs).
55. Remove the wiTECH scan tool from the vehicle.
56. Return the vehicle to the customer.

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Page 19

Service Procedure (Continued)

C. (DS) RAM 1500 Pickup
1. Saturate exhaust system fasteners with MOPAR rust penetrating lubricant or
equivalent before proceeding to provide adequate time for lubricant penetration
before exhaust component removal. Be sure to saturate the SCR catalyst flange
fasteners, Diesel Exhaust Fluid (DEF) injector clamp fastener, muffler to SCR
catalyst clamp, and tailpipe(s) to muffler clamp(s) (Figure 19).
MUFFLER TO SCR
CATALYST CLAMP

SCR CATALYST
FLANGE FASTENERS

DEF FLUID INJECTOR
CLAMP FASTENER
TAILPIPE TO
MUFFLER CLAMP

Figure 19 – Saturate Exhaust Fasteners with Penetrating Lubricant

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Service Procedure (Continued)
2. Disconnect the green exhaust
temperature
sensor
wire
harness connector located
between the exhaust particulate
filter and the vehicle frame
(Figure 20).

EXHAUST
PARTICULATE FILTER

VEHICLE FRAME

TEMPERATURE SENSOR WIRE
HARNESS CONNECTOR

Figure 20 – Exhaust Temperature Sensor

3. Disconnect the Diesel Exhaust
Fluid (DEF) injector wire
harness connector from the
DEF injector (Figure 21).

DEF
INJECTOR

DEF INJECTOR WIRE
HARNESS CONNECTOR

SCR
CATALYST

Figure 21 – DEF Injector Harness

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Service Procedure (Continued)

4. Slide the heat shielding cover
back and disconnect the DEF
fluid supply line quick connect
fitting from the DEF injector
(Figure 22).

5. Remove and save the three nuts
from the Oxides of Nitrogen
(NOx) and Particulate Matter
(PM) sensor module mounting
bracket.
Then remove the
bracket from the crossmember
(Figure 23).

MODULE
BRACKET

FRAME
CROSSMEMBER

NOX SENSOR
MODULE

DEF FLUID SUPPLY
LINE QUICK
CONNECT FITTING

HEAT
SHIELDING
COVER

DEF
INJECTOR

Figure 22 – DEF Injector Fitting

PM SENSOR
MODULE

REAR
PROPSHAFT

Figure 23 – PM and NOx Sensor Module Bracket on Crossmember

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Service Procedure (Continued)
6. Release the four NOx sensor
and PM sensor wire harness
retainers (Figure 24).

WIRE HARNESS
RETAINERS

NOTE: DO NOT disconnect
the PM sensor wire harness
connector from the PM sensor
module.
ONLY disconnect
the vehicle wire harness from
the PM sensor module (Figure
25).
7. Disconnect the vehicle wire
harness connector from the PM
sensor module (Figure 25).

PM SENSOR
WIRE HARNESS

NOX SENSOR

Figure 24 – Wire Harness Retainers

8. Remove and save the two nuts from the PM sensor module. Then remove the
PM sensor module from the module mounting bracket (Figure 25).
VEHICLE WIRE
HARNESS CONNECTOR

REAR
PROPSHAFT

PM SENSOR
MODULE NUTS

PM SENSOR
MODULE

Figure 25 – PM Sensor Module

MODULE
BRACKET

FRAME
CROSSMEMBER

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Page 23

Service Procedure (Continued)
9. Disconnect the vehicle wire harness connector from the NOx sensor
(Figure 26).
NOTE: DO NOT disconnect the NOx sensor wire harness connector from
the NOx sensor module. ONLY disconnect the vehicle wire harness from
the NOx sensor module (Figure 26).
10. Remove and save the two nuts from the NOx sensor module. Then remove the
NOx sensor module from the module mounting bracket (Figure 26).
11. Route the PM sensor and NOx sensor modules over to the SCR catalyst and
secure the wire harness and modules to the SCR catalyst for removal with SCR
catalyst later in the procedure.
MODULE
BRACKET

REAR
PROPSHAFT

VEHICLE WIRE
HARNESS CONNECTOR

NOx SENSOR
MODULE

Figure 26 – NOx Sensor Module

FRAME
CROSSMEMBER

NOx SENSOR
MODULE NUTS

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Page 24

Service Procedure (Continued)
12. Loosen the exhaust tailpipe clamp(s) (Figure 27).
13. Release the isolator(s) from the exhaust tailpipe(s) hanger rod (Figure 27).
14. Separate the exhaust tailpipe(s) from the muffler. Then remove and save the
tailpipe(s) (Figure 27).

EXHAUST TAILPIPE ISOLATORS

EXHAUST TAILPIPE CLAMPS

MUFFLER

Figure 27 – Tailpipes (Dual Exhaust Shown Single Exhaust Similar)