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Section 1576 (6.7L Engine (Service Information) - 2500 Hd): Removal

WARNING: This page is about a different car, the 2017 RAM 2500 HD. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect and isolate both negative and positive battery cables.
    GC0161582Courtesy of CHRYSLER GROUP, LLC
  2. Remove the oil dipstick (2).
  3. Remove the bolts (1) and the engine cover (3).
  4. Remove the hood. Refer to HOOD, REMOVAL .
  5. Detach both left side battery cables from battery tray.
  6. Remove the left side engine block-to-frame ground wire.
  7. Route the battery cables forward through other wire harness.
  8. Remove the right side negative battery cables from the engine block and position aside.
  9. Drain cooling system. Refer to STANDARD PROCEDURE .
  10. Recover A/C refrigerant. Refer to PLUMBING, STANDARD PROCEDURE .
  11. Remove the air cleaner body and air tube. Refer to BODY, AIR CLEANER, REMOVAL, 6.7L .
  12. Remove the fasteners securing the pressurized coolant bottle and pull forward to allow clearance for the wire harness.
    GC0155445Courtesy of CHRYSLER GROUP, LLC
  13. Disconnect the bulkhead wire harness connector (1).
    GC0174705Courtesy of CHRYSLER GROUP, LLC
  14. Disconnect the single wire harness connector (1).
  15. Remove the nut and the B+ cable from the Power Distribution Center (PDC).
  16. Remove the push pin fasteners securing the main wire harness to the cowl.
  17. Partially remove the cowl panel cover on left side to allow access to the main wire harness fastener.
  18. Remove the nut securing the main wire harness to the cowl and position aside the wire harness.
  19. Remove the hood latch. Refer to LATCH, HOOD, REMOVAL .
  20. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
  21. Remove the left and right wheel house splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE .
  22. Drain the engine oil.
  23. Install the drain plug and tighten to 50 N.m (37 ft. lbs.).
  24. Remove the support and lower the vehicle.
  25. Remove the radiator closure panel. Refer to PANEL, CLOSURE, RADIATOR, REMOVAL .
  26. Remove the radiator. Refer to RADIATOR, ENGINE COOLING, REMOVAL .
  27. Remove the belt tensioner. Refer to TENSIONER, BELT, REMOVAL .
    NOTE:

    Not necessary to drain power steering fluid.

  28. Remove the power steering pump with the cooler and position aside. Refer to PUMP, REMOVAL .
  29. Remove the upper and lower coolant hose from the engine.
    GC0137128Courtesy of CHRYSLER GROUP, LLC
  30. Remove the nuts (1) that secure the A/C suction line (3) and the A/C discharge line (4) to the A/C compressor (2).
  31. Disconnect the A/C suction and discharge lines from the A/C compressor and remove and discard the O-ring seals and gaskets.
  32. Install the plugs in, or tape over the opened refrigerant line fittings and compressor ports.
    GC0155188Courtesy of CHRYSLER GROUP, LLC
  33. Disconnect the block heater wire harness connector (1).
    GC0173999Courtesy of CHRYSLER GROUP, LLC
  34. Remove the nut (1) and the intake heater cable (2) from solenoid.
    GC0174019Courtesy of CHRYSLER GROUP, LLC
  35. Remove the pressurized coolant bottle lower coolant hose (1) from the coolant tube.
  36. Remove the generator. Refer to GENERATOR, REMOVAL .
  37. Remove the bolt and the oil dip stick tube.
  38. Remove the intake manifold. Refer to REMOVAL .
  39. Remove the nut securing the ground cable to frame on the left side.
  40. Remove the bolts securing the Powertrain Control Module (PCM) wire harness.
  41. Disconnect the transmission wire harness connector C2 from the PCM.
  42. If equipped, remove the generator above the fuel injection pump. Refer to GENERATOR, REMOVAL .
  43. Disconnect the fuel line quick connector at the fuel injection pump for wire harness routing. Refer to STANDARD PROCEDURE .
  44. Disconnect the fuel supply and return lines to the fuel filter housing.
  45. Disconnect the fuel heater and water in fuel sensor wire harness connector.
  46. Remove the starter solenoid wire harness connector.
  47. Remove the nut and the B+ cable from the starter.
  48. Detach the three engine harness retainers securing wire harness along the engine block.
  49. Remove the cylinder head cover and the rocker housing. Refer to COVER(S), CYLINDER HEAD, REMOVAL, 6.7L .
  50. Disconnect both the heater hoses from the engine.
  51. Remove the EGR cooler. Refer to COOLER, EGR, REMOVAL .
  52. Remove the two body plugs in cowl for push rod removal.
    GC0169609Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Mark the location of pushrods and crossheads for reinstallation.

  53. Remove the bolts (1), rocker arms (2) pedestal (3), and pushrods for cylinder No. 4, 5, and 6.
  54. Remove the intake manifold TMAP. Refer to SENSOR, TMAP, REMOVAL .
  55. Remove the fuel rail. Refer to RAIL, FUEL, REMOVAL .
    GC0173998Courtesy of CHRYSLER GROUP, LLC
  56. Remove the bolts (1) and the rear engine lifting bracket (2).
  57. Remove cylinders 5 and 6 fuel injector. Refer to REMOVAL .
    GC0108461Courtesy of CHRYSLER GROUP, LLC
  58. Remove the two cylinder head bolts (1 and 3), for cylinders No. 4 and No. 5.
  59. Install the Engine Lifting Bracket (special tool #9009, Bracket, Engine Lifting) (2). Tighten bolts to 105 N.m (77 ft. lbs.).
  60. Remove the transmission vent hose from the back of engine.
  61. Raise and support the vehicle.
    GC0155304Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Do not remove the elbow (1) from the turbocharger.

  62. Remove the V-clamp (2) from the exhaust pipe-to-tubrocharger outlet elbow connection.
    GC0174024Courtesy of CHRYSLER GROUP, LLC
  63. If equipped, remove the bolts and the transmission dust shield (2).
  64. Remove the bolts and the right side lower engine block bracket.
    GC0155215Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The access cover (2) is located on the right side of the converter housing. The torque converter bolts are removed through the access hole on the right side of the converter housing.

  65. Remove the torque converter access bolt (1) and loosen (3). Rotate the cover (2) to gain access to the torque converter bolts.
    GC0108441Courtesy of CHRYSLER GROUP, LLC
  66. Install the Barring Tool (special tool #7471B, Barring Tool) (1).
  67. Using the Barring Tool (special tool #7471B, Barring Tool) (1), rotate the engine and remove the torque converter bolts.
  68. On manual transmission models, remove the dual mass flywheel bolts.
  69. Remove the Barring Tool (special tool #7471B, Barring Tool) (1).
  70. Remove the right and left engine mount through-bolts and nuts.
  71. Remove the engine to transmission bolts.
    GC0157549Courtesy of CHRYSLER GROUP, LLC
  72. Remove the brake line retaining (2) and slightly bend the tap (1) down to allow for clearance.
  73. Remove the support and lower the vehicle.
  74. Attach the chain to the engine lifting brackets and a suitable engine hoist.
  75. Position a jack under the transmission for support.
  76. Using a suitable engine hoist, and while keeping engine level, lift straight up out and of the mounts.
  77. Raise the transmission up as far as it will go with a jack.
  78. Carefully remove the engine from the vehicle.
  79. If necessary, remove the bolts and the transmission adapter plate.
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