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Section 1581 (5.7L 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.
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.

GC0088009Courtesy of CHRYSLER GROUP, LLC
NOTE:

Do not use air tools to install (special tool #8984B, Fixture, Engine Lifting) Engine Lift Fixture (1) and Adapter (special tool #8984B, Fixture, Engine Lifting) Eagle (2).

  1. Install the engine lift fixture (special tool #8984B, Fixture, Engine Lifting) (1) and adapter (special tool #8984B, Fixture, Engine Lifting) Eagle (2).
  2. Position the engine in the engine compartment.
    GC0082900Courtesy of CHRYSLER GROUP, LLC
  3. Lower and align the engine (1) with the transmission (3).
  4. Install two transmission bell housing to engine block mounting bolts (2) finger tight.
    GC0082901Courtesy of CHRYSLER GROUP, LLC
  5. Lower the engine assembly until the engine mount through bolts (3) line up in the frame brackets (1).
  6. Raise and support the vehicle on a hoist.
    GC0082900Courtesy of CHRYSLER GROUP, LLC
  7. Install the remaining transmission bell housing to engine block mounting bolts (2) and tighten to 68 N.m (50 ft. lbs.).
    GC0092084Courtesy of CHRYSLER GROUP, LLC
  8. Install both the left and right side oil pan to transmission bolts (1) and tighten bolts to 54 N.m (40 ft. lbs.).
  9. Connect the transmission oil cooler lines at the oil pan and tighten bolts to 12 N.m (9 ft. lbs.).
    GC0082901Courtesy of CHRYSLER GROUP, LLC
  10. Install the engine mount through bolts (3) and nuts and tighten to 95 N.m (70 ft. lbs.).
    GC0081755Courtesy of CHRYSLER GROUP, LLC
  11. Install all torque converter-to-driveplate bolts (1) by hand, verify the torque converter is pulled flush to the driveplate and tighten bolts to 31 N.m (23 ft. lbs.).
    GC0085486Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    The structural dust cover must be installed as described in the Structural Dust Cover installation procedure. Failure to do so will cause severe damage to the cover.

  12. Install the structural dust cover (1). Refer to COVER, STRUCTURAL DUST, INSTALLATION  .
    GC0082902Courtesy of CHRYSLER GROUP, LLC
  13. Install the starter (1) and connect the starter wires. Refer to STARTER, INSTALLATION .
    GC0080046Courtesy of CHRYSLER GROUP, LLC
  14. Install the front exhaust pipe/catalytic converter assembly (4) to the exhaust manifold flange and tighten the bolts and nuts (3) to 26 N.m (19 ft. lbs.).
  15. Lower the vehicle.
    GC0088009Courtesy of CHRYSLER GROUP, LLC
  16. Remove the engine lift fixture (special tool #8984B, Fixture, Engine Lifting) and adapter (special tool #8984B, Fixture, Engine Lifting) Eagle (1, 2).
    GC0088008Courtesy of CHRYSLER GROUP, LLC
  17. Install the VVTS and securely tighten fastener (1).
  18. Connect the VVTS electrical connector (2).
  19. Install the intake manifold. Refer to MANIFOLD, INTAKE, INSTALLATION  .
  20. Connect the fuel supply line. Refer to STANDARD PROCEDURE - QUICK-CONNECT FITTINGS .
    GC0083625Courtesy of CHRYSLER GROUP, LLC
  21. Install the three power steering pump mounting bolts through the access holes in the pulley (1) and tighten bolts to 28 N•m (21 ft. lbs.).
    GC0087999Courtesy of CHRYSLER GROUP, LLC
  22. Connect the heater hoses (2) and the lower radiator hose (1).
    GC0081752Courtesy of CHRYSLER GROUP, LLC
  23. Install the generator (2) and electrical connections. Refer to GENERATOR, INSTALLATION .
    GC0081750Courtesy of CHRYSLER GROUP, LLC
  24. Install the A/C compressor (3). Refer to COMPRESSOR, A/C, INSTALLATION .
    GC0085492Courtesy of CHRYSLER GROUP, LLC
  25. Connect the refrigerant lines (1, 3) to the A/C compressor (4) and tighten the nuts (2) to 20 N.m (15 ft. lbs.).
  26. Install the viscous fan drive assembly. Refer to FAN, COOLING, VISCOUS, REMOVAL .
    GC0087997Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

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

  27. Insert a suitable square drive ratchet into the square hole on the belt tensioner arm (7).
  28. Rotate the tensioner (7) counter-clockwise and install the accessory drive belt (4).
  29. Install the radiator and A/C condenser as an assembly. Refer to RADIATOR, ENGINE COOLING, INSTALLATION and CONDENSER, A/C, INSTALLATION .
  30. Position the shroud in the radiator tank clips and Install the fan shroud mounting bolts.
  31. Connect the radiator upper hose.
    GC0087421Courtesy of CHRYSLER GROUP, LLC
  32. Position the upper radiator seal and install the two plastic rivets (2).
  33. Install the four push pins (1).
  34. Install the washer bottle.
    GC0087996Courtesy of CHRYSLER GROUP, LLC
  35. Install the engine cover (1). Refer to COVER, ENGINE, INSTALLATION  .
  36. Install the air cleaner housing (4).
  37. Install the clean air hose (2).
  38. Connect the intake air temperature (IAT) sensor electrical connector (3).
    GC0087848Courtesy of CHRYSLER GROUP, LLC
  39. Fill the engine with oil. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
  40. Fill the cooling system. Refer to STANDARD PROCEDURE .
  41. Connect the negative battery cable (1).
  42. Start the engine and check for leaks.
  43. Evacuate and Charge the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE .
NOTE:

The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components.

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