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Section 655 (6.4L Engine (Service Information) 2500 Hd & 3500 Hd): Installation: Installation

WARNING: This page is about a different car, the 2014 RAM 3500 HD and 2014 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.

Fig 1: Engine Lift Fixture & Adapter
GC0088009Courtesy of CHRYSLER GROUP, LLC
NOTE:

Do not use air tools to install the (special tool #8984B, Fixture, Engine Lifting) and (special tool #2013800090, Adapter, Engine Lifting Bracket).

  1. If required, install the following components for installation on the replacement engine:
    • Engine wiring harness.
    • Upper and lower intake manifold and brackets.
    • Sensors.
    • Timing chain cover.
    • Crankshaft Damper.
    • Accessory drive belt tensioner.
    • Accessory drive belt.
    • Block heater (if equipped).
  2. Install the engine lift fixture (1) and adapter (2).
  3. Position the engine in the engine compartment.
    Fig 2: Remove/Install Transmission To Engine Bolts
    GC0082900Courtesy of CHRYSLER GROUP, LLC
  4. Lower and align the engine (1) to the transmission (3).
  5. Install two transmission bell housing to engine block mounting bolts (2) finger tight.
    Fig 3: Engine Mount & Bolt
    GC0082901Courtesy of CHRYSLER GROUP, LLC
  6. Lower the engine assembly until the engine mount through bolts (3) line up in the frame brackets (1).
  7. Raise and support the vehicle on a hoist.
    Fig 4: Remove/Install Transmission To Engine Bolts
    GC0082900Courtesy of CHRYSLER GROUP, LLC
  8. Install the remaining transmission bell housing to engine block mounting bolts (2) and tighten to 68 N.m (50 ft. lbs.).
    Fig 5: Oil Pan To Transmission Bolts
    GC0092084Courtesy of CHRYSLER GROUP, LLC
  9. Install both the left and right side oil pan to transmission bolts (1) and tighten bolts to 54 N.m (40 ft. lbs.).
  10. Connect the transmission oil cooler lines at the oil pan and tighten bolts to 12 N.m (9 ft. lbs.).
    Fig 6: Engine Mount & Bolt
    GC0082901Courtesy of CHRYSLER GROUP, LLC
  11. Install the engine mount through bolts (3) and nuts and tighten to 95 N.m (70 ft. lbs.).
    Fig 7: Drive Plate Torque Converter Bolts
    GC0081755Courtesy of CHRYSLER GROUP, LLC
  12. 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.).
    Fig 8: Structural Dust Cover
    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.

  13. Install the structural dust cover (1). Refer to COVER, STRUCTURAL DUST, INSTALLATION .
    Fig 9: Starter Mounting Bolts
    GC0087582Courtesy of CHRYSLER GROUP, LLC
  14. Install the starter (1) and connect the starter wires. Refer to STARTER, INSTALLATION .
    Fig 10: Exhaust Pipe To Manifold Bolts
    GC0161577Courtesy of CHRYSLER GROUP, LLC
  15. Install the front exhaust pipe/catalytic converter assembly to the exhaust manifold flange and tighten the bolts and nuts (1, 2) to 26 N.m (19 ft. lbs.).
    Fig 11: Oxygen Sensors & Electrical Connectors
    GC0161549Courtesy of CHRYSLER GROUP, LLC
  16. Connect the O2 sensors electrical connectors (1, 2).
  17. Lower the vehicle.
    Fig 12: Engine Lift Fixture & Adapter
    GC0088009Courtesy of CHRYSLER GROUP, LLC
  18. Remove the engine lift fixture (1) (special tool #8984B, Fixture, Engine Lifting) and adapter (2) (special tool #2013800090, Adapter, Engine Lifting Bracket) Eagle (1, 2).
    Fig 13: Oil Control Valve
    GC0088008Courtesy of CHRYSLER GROUP, LLC
  19. Install the VVTS (1) and securely tighten fastener.
  20. Connect the VVTS electrical connector (2).
    Fig 14: Remove/Install EGR Cooler
    GC0161631Courtesy of CHRYSLER GROUP, LLC
  21. Install the EGR cooler (2). Refer to COOLER, EGR, INSTALLATION .
    Fig 15: Intake Manifold Removal/Installation Sequence
    GC0161638Courtesy of CHRYSLER GROUP, LLC
  22. Install the intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL  .
  23. Connect the fuel supply line. Refer to FITTING, QUICK CONNECT .
    Fig 16: Power Steering Pump Pulley & Bolts
    GC0158436Courtesy of CHRYSLER GROUP, LLC
  24. Install the three power steering pump mounting bolts (2) through the access holes in the pulley (1) and tighten bolts to 28 N.m (21 ft. lbs.).
    Fig 17: Generator, Insulator Cap, B+ Output Terminal & Connector
    GC0161535Courtesy of CHRYSLER GROUP, LLC
  25. If equipped, install the lower generator (3) and electrical connections. Refer to GENERATOR, INSTALLATION .
    Fig 18: Lower Radiator Hose
    GC0158447Courtesy of CHRYSLER GROUP, LLC
  26. Connect the heater hoses (3) and the lower radiator hose (5).
  27. Install the oil cooler (7) return hose (6).
    Fig 19: Generator, Bolts & Connector
    GC0158421Courtesy of CHRYSLER GROUP, LLC
  28. Install the generator (1) and electrical connections. Refer to GENERATOR, INSTALLATION .
    Fig 20: Removing/Installing A/C Compressor
    GC0154471Courtesy of CHRYSLER GROUP, LLC
  29. Install the A/C compressor (1). Refer to COMPRESSOR, A/C, INSTALLATION .
    Fig 21: A/C Line P-Clip & Retaining Bolt
    GC0088123Courtesy of CHRYSLER GROUP, LLC
  30. Install the refrigerant lines to the upper bracket. Tighten the bolt (1) to 12 N.m (9 ft. lbs.).
    Fig 22: Accessory Drive Belt, Tensioner & Pulleys
    GC0087997Courtesy of CHRYSLER GROUP, LLC
  31. Insert a suitable square drive ratchet into the square hole on the belt tensioner arm (7).
    CAUTION:

    Do not let the tensioner arm snap back to the freearm position, severe damage may occur to the tensioner.

  32. Rotate the tensioner (7) counter-clockwise and install the accessory drive belt (4).
    Fig 23: Removing/Installing Belt
    GC0161593Courtesy of CHRYSLER GROUP, LLC
  33. If equipped, install the secondary generator drive belt (3). Refer to BELT, SERPENTINE, INSTALLATION .
  34. Install the radiator and A/C condenser as an assembly. Refer to RADIATOR, ENGINE COOLING, INSTALLATION and CONDENSER, A/C, INSTALLATION .
    Fig 24: Upper & Lower Shrouds
    GC0158432Courtesy of CHRYSLER GROUP, LLC
  35. Install the viscous fan drive assembly. Refer to FAN, COOLING, VISCOUS, REMOVAL .
  36. Position the shroud (1) on the radiator tank clips and install the fan shroud.
  37. Install the lower fan shroud (2).
    Fig 25: Upper Radiator Hose
    GC0161633Courtesy of CHRYSLER GROUP, LLC
  38. Install the upper radiator hose (4).
    Fig 26: Upper Radiator Seal & Plastic Rivets
    GC0087421Courtesy of CHRYSLER GROUP, LLC
  39. Install the washer bottle.
  40. Position the upper radiator seal and install the two plastic rivets (2).
  41. Install the four push pins (1).
  42. Install the engine cover (1).
    Fig 27: Air Cleaner Housing & Tabs
    GC0161591Courtesy of CHRYSLER GROUP, LLC
  43. Install the air cleaner housing (1).
    Fig 28: Clamp, Air Intake Tube & Breather Hose
    GC0161561Courtesy of CHRYSLER GROUP, LLC
  44. Install the intake hose (2). Hand tighten clamp.
  45. Install the breather hose (3).
    Fig 29: Temperature Sensor
    GC0161541Courtesy of CHRYSLER GROUP, LLC
  46. Connect the Intake Air Temperature (IAT) sensor electrical connector (2).
  47. Connect the Mass Air Flow (MAF) sensor (1).
  48. Fill the engine with oil. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
  49. Fill the cooling system. Refer to STANDARD PROCEDURE .
  50. Connect the negative battery cable.
  51. Start the engine and check for leaks.
  52. If required, evacuate and charge the A/C system. Refer to PLUMBING, STANDARD PROCEDURE .
  53. Install the Hood (Refer to HOOD, INSTALLATION ).
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