Torque exhaust manifold - 2005 Dodge Ram 1500

Hi Jesse,here's a Autozone repair guide on your exhaust manifold. Repair Guides Engine Mechanical Components Exhaust Manifold AutoZone com

Exhaust Manifold To Cylinder Head - 9.58 ft lbs
Exhaust Pipe To Exhaust Manifold - 20 ft lbs
you can check it out here, also all other torque specs for your engine.
Torque Specs Database

Fig. Left side exhaust manifold bolt torque sequence-3.0L engine




Fig. Right side exhaust manifold bolt torque sequence-3.0L engine

Both cases, exhaust manifold and new gasket, torque the bolts to 15 ft. lbs. (20 Nm).

Good luck (remember to rate this answer).

According to the service literature I read, the 2003 Montero Sport with the 3.0 or 3.5 L engine does not have O2 sensors listed even in the maintenance schedule. The 2.4 L engine has it on the exhaust manifold though.
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However, the following lists the par, though for before or after the catalytic converter:

http://www.partstrain.com/store/index.php?VN=4294967180+4294966587+4294964143+&Nr=AND(universal:0)&N=0&Ntt=Oxygen%20Sensor

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I think that $250 to $300 is reasonable if the Oxygen sensors are stuck in there with rust and the threads are preserved by the technician. Oxygen Sensor replacement can be tricky.
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Good luck on this repair.

Exhaust Manifold

REMOVAL & INSTALLATION

2.4L Engine

1. Remove or disconnect the following:
   
   
   
   • Negative battery cable
   
   CAUTION
   Wait at least 90 seconds after the negative
   battery cable is disconnected to prevent possible deployment of the air bag.
   
   
   
2. Heat cowl from the exhaust manifold
   
3. Aspirator valve assembly, if equipped
   
4. Oil dipstick and guide
   
5. Oxygen (O2S) sensor connector and ground cable, if equipped
   
6. Exhaust pipe from the manifold
   
7. Exhaust manifold and gasket from the engine
   To install:
   
   
8. Install or connect the following:
   
   
   
   • Exhaust manifold. Torque the M8 mounting nuts to 22 ft. lbs. (29 Nm) and the
     M10 mounting bolts 36 ft. lbs. (49 Nm). starting from the middle and working
     outward.
     
   • O2S sensor connector and ground cable, if equipped
     
   • Exhaust pipe to the manifold. Torque the nuts to 35ft. (49 Nm).
     
   • Aspirator valve assembly, if removed
     
   • Heat cowl to the exhaust manifold. Torque the bolts to 117 inch lbs. (13
     Nm).
     
   • Negative battery cable
   
   
9. Start the engine and check for exhaust leaks.

3.0L and 3.5L Engines

1. Remove or disconnect the following:
   
   
   
   • Negative battery cable
     
   • Exhaust pipe from the exhaust manifolds
     
   • Oil dipstick, guide and O-ring
     
   • Heat shields
     
   • Exhaust manifolds
   
   
2. Clean the gasket mounting surfaces. Inspect the manifolds for cracks,
   flatness and/or damage.
   To install:
   
   
3. Install or connect the following:
   
   
   
   • New gasket and exhaust manifold. Torque the nuts to 33 ft. lbs. (44 Nm) on
     3.0L engines and 22 ft. lbs. (29 Nm) on 3.5L engines.
     
   • Heat shield, Torque the bolts to 10 ft. lbs. (14 Nm).
     
   • Exhaust pipe to the exhaust manifolds. Torque the nuts to 35ft. (49 Nm).
     
   • Oil dipstick, guide and new O-ring
     
   • Negative battery cable
   
   
4. Start the engine and check for exhaust leaks.

Exhaust Manifold - Removal & Installation3.0L Engine

1. Before servicing the vehicle, please familiarize yourself with safety procedures.
2. Remove or disconnect the following:
   Negative battery cable Heat shields Lower splash shields Exhaust front pipes Secondary air tubes Exhaust Gas Recirculation (EGR) tube Exhaust manifold
   

To install:



Fig. Right exhaust manifold torque sequence-3.0L engine



Fig. Left exhaust manifold torque sequence-3.0L engine

1. Install the exhaust manifolds. Tighten the fasteners in sequence as follows:
   1. Step 1: 15 ft. lbs. (20 Nm)
   2. Step 2: 15 ft. lbs. (20 Nm)
      
2. Install or connect the following:
   Exhaust Gas Recirculation (EGR) tube Secondary air tubes Exhaust front pipes Lower splash shields Heat shields Negative battery cable
3. Start the engine and check for leaks.

continue...

Exhaust manifold bolts-first pass 11 Lb/Ft. Exhaust manifold bolts-final pass 18 Lb/Ft. Exhaust manifold heat shield bolts 7 Lb/Ft. Note: To torque bolts & nuts, start in center using crisscross pattern working outward

Cylinder Head Bolt Step1- (25 FT.Lbs) Step2(45 Ft.Lbs) Step3(65Ft,Lbs).....Intake Manifold(35Ft Lbs)....Exhaust Manifold Center (20Ft Lbs) All Others (20 Ftlbs).....Thanks

2.4 enigine is the harder of the 3 enignes. it will need a timing chain to be removed and a coolant tube in the back of the engine to be removed. this job on the book calls for almost 7 hours.

if its 3.3 or 3100 its alot easier.

3100 is just 4 10mm pulley bolts and 5 or 6 small 8mm water pump bolts.

3.3 is alittle more work, but same concept as 3100 engine. more owkr only cause its in a tighter area.

good luck,
michael