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

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. If removed, install the transmission adapter plate. Refer to PLATE, TRANSMISSION ADAPTER, INSTALLATION, 6.7L .
    GC0108461Courtesy of CHRYSLER GROUP, LLC
  2. If necessary, remove the cylinder head bolts (1 and 3) for cylinders 4 and 5.
  3. If necessary, install the Engine Lifting Bracket (special tool #9009, Bracket, Engine Lifting) (2). Tighten bolts to 105 N.m (77 ft. lbs.).
  4. Attach the chain to the engine lifting brackets and a suitable engine hoist.
  5. Position the engine into the engine compartment and carefully lower and install the engine into mount.
  6. Install the engine mount through-bolts and nuts and tighten to 136 N.m (100 ft. lbs.).
  7. Remove the chains and engine hoist.
  8. Lower the transmission and remove the jack.
  9. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
    GC0157549Courtesy of CHRYSLER GROUP, LLC
  10. Bend the tap (1) up and install the brake line retainer (2).
  11. Install the transmission to engine bolts:
    GC0108441Courtesy of CHRYSLER GROUP, LLC
  12. Install the Barring Tool (special tool #7471B, Barring Tool) (1).
  13. Using the Barring Tool (special tool #7471B, Barring Tool) (1), rotate the engine and install the torque converter bolts. Tighten the bolts to 95 N.m (65 ft. lbs.).
  14. On manual transmission models, install the dual mass flywheel bolts. Tighten bolts to 61 N.m (45 ft. lbs.).
  15. Remove the Barring Tool (special tool #7471B, Barring Tool) (1).
    GC0155215Courtesy of CHRYSLER GROUP, LLC
  16. Install the torque converter access cover (2). Tighten the bolts (1, 3) to 10 N.m (89 in. lbs.).
  17. Install the right side lower engine block bracket. Tighten the bolts to 89 N.m (66 ft. lbs.).
    GC0174024Courtesy of CHRYSLER GROUP, LLC
  18. If equipped, install the transmission dust shield (2) and securely tighten the bolts (1).
    GC0155304Courtesy of CHRYSLER GROUP, LLC
  19. Using a NEW  V-clamp and gasket, install the exhaust pipe to the turbocharger elbow (1). Tighten the V-clamp to 18 N.m (13 ft. lbs.).
  20. Remove the support and lower the vehicle.
  21. Install the transmission vent hose to the back of engine.
  22. Remove the Engine Lifting Bracket (special tool #9009, Bracket, Engine Lifting) (2).
  23. Check the cylinder head bolt length and install into cylinders No. 4 and No. 5.
  24. Tighten the head bolts to:
    • Step 1 Tighten to 70 N.m (52 ft. lbs.).
    • Step 2 Back off 360°.
    • Step 3 Tighten to 105 N.m (77 ft. lbs.).
    • Step 4 Rotate 90°.
  25. Install cylinders 5 and 6 fuel injector. Refer to INSTALLATION .
    GC0173998Courtesy of CHRYSLER GROUP, LLC
  26. Install the rear engine lifting bracket (2) and tighten the bolts (1) to 83 N.m (61 ft. lbs.).
  27. Install the fuel rail. Refer to RAIL, FUEL, INSTALLATION .
  28. Install the intake manifold TMAP. Refer to SENSOR, TMAP, INSTALLATION .
    GC0169609Courtesy of CHRYSLER GROUP, LLC
  29. Install the pushrods, rocker arms (1), and pedestals (2) for cylinders No. 4, No. 5, and No. 6. Tighten the bolts (1) to 36 N.m (27 ft. lbs.).
  30. Adjust the intake and exhaust valve lash on cylinders 4, 5, and 6. Refer to STANDARD PROCEDURE  .
  31. Install the two plugs into cowl.
  32. Install the EGR cooler. Refer to COOLER, EGR, INSTALLATION .
  33. Connect both the heater hoses to engine.
  34. Install the rocker housing and the cylinder head cover. Refer to COVER(S), CYLINDER HEAD, INSTALLATION, 6.7L .
  35. Attach the three engine harness retainers securing wire harness along the engine block.
  36. Install the B+ cable to the starter and tighten the nut to 24 N.m (18 ft. lbs.).
  37. Install the starter solenoid wire harness connector.
  38. Connect the fuel heater and water in fuel sensor wire harness connector.
  39. Connect the fuel supply and return lines to the fuel filter housing.
  40. Connect the fuel line quick connector at the fuel injection pump.
  41. If equipped, install the generator above the fuel injection pump. Refer to GENERATOR, INSTALLATION .
  42. Connect the transmission wire harness connector C2 to the Powertrain Control Module (PCM).
  43. Install the bolts securing the PCM wire harness to the PCM.
  44. Install the nut securing the ground cable to frame on the left side and securely tighten.
  45. Install the intake manifold. Refer to INSTALLATION .
  46. Install the oil dip stick tube and tighten the bolt to 24 N.m (18 ft. lbs.).
  47. Install the generator. Refer to GENERATOR, INSTALLATION .
    GC0174019Courtesy of CHRYSLER GROUP, LLC
  48. Install the pressurized coolant bottle lower coolant hose (1) to the coolant tube.
    GC0173999Courtesy of CHRYSLER GROUP, LLC
  49. Install the intake air heater cable (2) to the solenoid. Tighten the nut (1) to 10 N.m (89 in. lbs.).
    GC0155188Courtesy of CHRYSLER GROUP, LLC
  50. Connect the engine block heater harness connector (1).
    GC0137128Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Lower radiator hose removed for clarity.

  51. Remove the tape or plugs from the opened refrigerant line fittings and compressor ports.
    NOTE:

    Use only the specified O-ring seals as they are made of a special material for the R-134a system.

    NOTE:

    Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

  52. Lubricate the NEW  O-ring seals and the NEW  gasket with clean refrigerant oil and install them onto the refrigerant line fittings.
  53. Install the A/C suction line (3) and A/C discharge line (4) to the A/C compressor (2). Tighten the nuts (1) to 23 N.m (17 ft. lbs.).
  54. Install the upper and lower coolant hose onto the engine.
  55. Install the power steering pump. Refer to PUMP, INSTALLATION .
  56. Install the belt tensioner. Refer to TENSIONER, BELT, INSTALLATION .
  57. Install the radiator. Refer to RADIATOR, ENGINE COOLING, INSTALLATION .
  58. Install the radiator closure panel. Refer to PANEL, CLOSURE, RADIATOR, INSTALLATION .
  59. Raise and support the vehicle.
  60. Install the left and right wheel house splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE .
  61. Remove the support and lower the vehicle.
  62. Position the main wire harness back unto the cowling and install the nut and securely tighten.
  63. Install the left side cowl panel cover.
  64. Install the push pin fasteners securing the main wire harness to the cowl.
  65. Install the B+ cable to the Power Distribution Center (PDC) and securely tighten the nut.
    GC0174705Courtesy of CHRYSLER GROUP, LLC
  66. Connect the single wire harness connector (1).
    GC0155445Courtesy of CHRYSLER GROUP, LLC
  67. Connect the bulkhead wire harness connector (1).
  68. Install the air cleaner body and air tube. Refer to BODY, AIR CLEANER, INSTALLATION, 6.7L .
  69. Evacuate and recharge A/C system. Refer to PLUMBING, STANDARD PROCEDURE .
  70. Fill the cooling system with coolant. Refer to STANDARD PROCEDURE .
  71. Change the oil filter and fill with recommended engine oil.
  72. Install the right side negative battery cables to the engine block and securely tighten.
  73. Route the battery cables forward through other wire harness.
  74. Install the negative battery cables on the left side and right side of engine block.
  75. Install the left side engine block-to-frame ground wire.
  76. Attach both left side battery cables to the battery tray.
  77. Install the hood. Refer to HOOD, INSTALLATION .
  78. Connect both negative and positive battery cables.
  79. Start the engine and inspect for engine oil, coolant, and fuel leaks.
    GC0161582Courtesy of CHRYSLER GROUP, LLC
  80. Install the engine cover (3). Tighten the bolts (1) to 10 N.m (89 in. lbs.).
  81. Install the oil dipstick (2).
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