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Section 1577 (6.4L 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.
CAUTION:

If the original engine has experienced a catastrophic failure or an individual failure with the piston, cylinder bore, engine block, valve or valve seat, the intake manifold MUST be replaced with a new manifold.

GC0161541Courtesy of CHRYSLER GROUP, LLC
  1. Remove the Hood. Refer to HOOD, REMOVAL .
  2. Remove the engine cover.
  3. Disconnect the Intake Air Temperature (IAT) sensor harness connector (2).
  4. Disconnect the Mass Air Flow (MAF) sensor harness connector (1).
    GC0161561Courtesy of CHRYSLER GROUP, LLC
  5. Remove the breather hose (3) from the intake air hose (2).
  6. Loosen the clamp (1) that secure the intake air hose to the throttle body.
    GC0161591Courtesy of CHRYSLER GROUP, LLC
  7. Using care, lift the air cleaner housing (1) off the tabs (2).
  8. Perform the Fuel System Pressure Release procedure. Refer to FUEL SYSTEM PRESSURE RELEASE .
    GC0087848Courtesy of CHRYSLER GROUP, LLC
  9. Disconnect the negative battery cable.
    WARNING:

    Do not remove or loosen the radiator draincock with system hot and under pressure. Serious burns from coolant can occur.

  10. Drain the cooling system. Refer to STANDARD PROCEDURE .
    GC0161593Courtesy of CHRYSLER GROUP, LLC
  11. If equipped with dual generators (1), remove the secondary belt (3). Refer to BELT, SERPENTINE, REMOVAL .
    CAUTION:

    Do not let the tensioner arm snapback to the fully extended position, severe damage may occur to the tensioner.

    GC0087997Courtesy of CHRYSLER GROUP, LLC
  12. Insert a suitable square drive ratchet into the square hole on the belt tensioner arm (7).
  13. Release the belt tension by rotating the tensioner clockwise until the accessory drive belt can be removed from the generator pulley only (2).
    GC0087421Courtesy of CHRYSLER GROUP, LLC
  14. Remove the upper radiator seal push pins (1).
  15. Remove the plastic rivets (2) and remove the upper radiator seal.
    GC0158432Courtesy of CHRYSLER GROUP, LLC
  16. Remove the lower shroud (2).
  17. Remove the upper fan shroud (1) from the radiator tank clips. Refer to FAN, COOLING, VISCOUS, REMOVAL - 6.4L .
    CAUTION:

    Do not place the viscous fan drive in horizontal position. If stored horizontally, silicone fluid in the viscous fan drive could drain into its bearing assembly and contaminate lubricant.

  18. Remove the viscous fan drive assembly. Refer to FAN, COOLING, VISCOUS, REMOVAL - 6.4L .
  19. Remove the radiator.
  20. Recover the A/C system. Refer to PLUMBING, STANDARD PROCEDURE .
    GC0161633Courtesy of CHRYSLER GROUP, LLC
  21. Remove the upper radiator hose (4).
    GC0158097Courtesy of CHRYSLER GROUP, LLC
  22. Remove the A/C lines at the support bracket (2).
    GC0154471Courtesy of CHRYSLER GROUP, LLC
  23. Remove the A/C compressor (1). Refer to COMPRESSOR, A/C, REMOVAL .
    GC0158421Courtesy of CHRYSLER GROUP, LLC
  24. Disconnect the generator electrical connectors and remove the generator assembly (1). Refer to GENERATOR, REMOVAL .
    GC0158447Courtesy of CHRYSLER GROUP, LLC
  25. Disconnect the heater hose (3) and lower radiator hose (5) at the water pump (1).
  26. If equipped with an oil cooler (7). Remove the return hose (6).
    NOTE:

    It is not necessary to disconnect the power steering hoses from the power steering pump, for power steering pump removal.

    GC0158436Courtesy of CHRYSLER GROUP, LLC
  27. Remove the three bolts (2) securing the power steering pump through the holes in the pulley (1) and secure the power steering pump out of the way.
    GC0161535Courtesy of CHRYSLER GROUP, LLC
  28. Remove the lower generator (3). Refer to GENERATOR, REMOVAL .
  29. Disconnect the fuel supply line. Refer to STANDARD PROCEDURE - QUICK-CONNECT FITTINGS .
  30. Raise and support the vehicle on a hoist and drain the engine oil.
    GC0082897Courtesy of CHRYSLER GROUP, LLC
  31. Loosen both front engine mount through bolts (3).
  32. Disconnect the transmission oil cooler lines from their retainers at the oil pan bolts.
    GC0161549Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    When servicing or replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing the exhaust to hang by the oxygen sensor wires will damage the harness or sensor.

  33. Disconnect the oxygen sensor electrical connectors (1, 2).
  34. Saturate all exhaust bolts and nuts with Mopar® Rust Penetrant. Allow 5 minutes for penetration.
    GC0161577Courtesy of CHRYSLER GROUP, LLC
  35. Remove the exhaust pipe to manifold bolts (1, 2) and disconnect the front exhaust pipe/catalytic converter assembly at the exhaust manifolds.
    GC0087582Courtesy of CHRYSLER GROUP, LLC
  36. Disconnect the starter wires and remove the starter (1). Refer to STARTER, REMOVAL .
    GC0085486Courtesy of CHRYSLER GROUP, LLC
  37. Remove the transmission inspection and structural dust covers (2). Refer to COVER, STRUCTURAL DUST, REMOVAL .
    GC0081755Courtesy of CHRYSLER GROUP, LLC
  38. Remove the drive plate to converter bolts (Automatic transmission equipped vehicles).
    GC0092084Courtesy of CHRYSLER GROUP, LLC
  39. Remove both the left and right side oil pan to transmission bolts (1).
    GC0082899Courtesy of CHRYSLER GROUP, LLC
  40. Remove the transmission bell housing to engine block bolts (2).
  41. Lower the vehicle.
    Fig 1: Intake Manifold Removal/Installation Sequence
    GC0161638Courtesy of CHRYSLER GROUP, LLC
  42. Remove the intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL  .
    GC0161631Courtesy of CHRYSLER GROUP, LLC
  43. Remove the EGR cooler (2). Refer to COOLER, EGR, REMOVAL .
    NOTE:

    To remove the VVTS, the engine must be at room temperature.

    GC0088008Courtesy of CHRYSLER GROUP, LLC
  44. Remove the VVTS electrical connector (2).
  45. Remove the VVTS retaining bolt.
    GC0088009Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Do not use air tools to install the (special tool #8984B, Fixture, Engine Lifting) (1) and (special tool #2013800091, Adapter, Engine Lifting Bracket).

  46. Install the engine lift fixture (1) and adapter.
  47. Support the transmission with a suitable transmission jack.
  48. Separate the engine from the transmission and remove engine from the vehicle.
  49. If required, remove the following components for installation on the replacement engine:
    • Remove the accessory drive belt.
    • Engine wiring harness.
    • Upper and lower intake manifold and brackets.
    • Sensors.
    • Timing chain cover.
    • Crankshaft Damper.
    • Accessory drive belt tensioner.
    • Block heater (if equipped).
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