Ram 1500, 2500, 3500, 2WD and 4WD, 2001-2005

Engine

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Recover the A/C refrigerant, if equipped.
  8.  
  9. Remove or disconnect the following:

    Both battery negative cables
     
    Hood
     
    Upper crossmember and top core support
     
    Transmission oil cooler, if equipped
     
    Accessory drive belt
     
    A/C compressor
     
    Washer fluid bottle
     
    Coolant recovery bottle
     
    A/C condenser, if equipped
     
    Radiator hoses
     
    Cooling fan and shroud
     
    Radiator
     
    Alternator
     
    Heater hoses
     
    Air inlet tube
     
    Exhaust front pipe
     
    Intercooler inlet and outlet ducts
     
    Accelerator linkage
     
    Cruise control cable, if equipped
     
    Transmission cable, if equipped
     
    Power steering hoses
     
    Transmission oil cooler lines, if equipped
     
    Engine control sensor harness connectors
     
    Fuel lines
     
    Transmission
     
    Oil pan
     
    Starter motor
     
    Install engine hoist
     
    Engine mounts
     
    Engine
     

  10.  

To install:

  1. Install or connect the following:

    Engine. Tighten the through bolts to 57 ft. lbs. (77 Nm).
     
    Starter motor
     
    Oil pan
     
    Transmission
     
    Fuel lines
     
    Engine control sensor harness connectors
     
    Transmission oil cooler lines, if equipped
     
    Power steering hoses
     
    Transmission cable, if equipped
     
    Cruise control cable, if equipped
     
    Accelerator linkage
     
    Intercooler inlet and outlet ducts
     
    Exhaust front pipe
     
    Air inlet tube
     
    Heater hoses
     
    Alternator
     
    Radiator
     
    Cooling fan and shroud
     
    Radiator hoses
     
    A/C condenser, if equipped
     
    Coolant recovery bottle
     
    Washer fluid bottle
     
    A/C compressor
     
    Accessory drive belt
     
    Transmission oil cooler, if equipped
     
    Upper crossmember and top core support
     
    Hood
     
    Battery
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Fill the crankcase to the correct level.

    Recharge the A/C system, if equipped.
     

  6.  
  7. Start the engine and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Recover the A/C refrigerant, if equipped.
  6.  
  7. Drain the engine oil.
  8.  
  9. Relieve the fuel system pressure.
  10.  
  11. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Grille
     
    Radiator support brace
     
    Inside engine cover
     
    Air cleaner assembly
     
    Transmission oil cooler, if equipped
     
    Radiator hoses
     
    Heater hoses
     
    Radiator and fan shroud
     
    A/C condenser
     
    Accessory drive belt
     
    Power steering pump
     
    Air injection pump
     
    Intake manifold vacuum lines
     
    Washer solvent bottle
     
    A/C compressor, if equipped
     
    Throttle linkage
     
    Engine control sensor harness connectors
     
    Alternator
     
    Cooling fan
     
    Distributor cap and spark plug wires
     
    Fuel line
     
    Throttle body
     
    Fuel supply manifold
     
    Intake manifold
     
    Exhaust front pipe
     
    Starter motor
     
    Transmission
     
    Engine mounts
     
    Engine
     

  12.  

To install:

  1. Install or connect the following:

    Engine. Tighten the mount bolts to 30 ft. lbs. (41 Nm) and the nuts to 75 ft. lbs. (101 Nm).
     
    Transmission
     
    Starter motor
     
    Exhaust front pipe
     
    Intake manifold
     
    Fuel supply manifold
     
    Throttle body
     
    Fuel line
     
    Distributor cap and spark plug wires
     
    Cooling fan
     
    Alternator
     
    Engine control sensor harness connectors
     
    Throttle linkage
     
    A/C compressor, if equipped
     
    Washer solvent bottle
     
    Intake manifold vacuum lines
     
    Air injection pump
     
    Power steering pump
     
    Accessory drive belt
     
    A/C condenser
     
    Radiator and fan shroud
     
    Heater hoses
     
    Radiator hoses
     
    Transmission oil cooler, if equipped
     
    Air cleaner assembly
     
    Inside engine cover
     
    Radiator support brace
     
    Grille
     
    Hood
     
    Negative battery cable
     

  2.  
  3. Fill the crankcase to the correct level.
  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

3.7L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Air cleaner assembly
     
    Radiator
     
    Electric and mechanical fan assemblies
     
    A/C compressor, if equipped, and secure it out of the way with the lines attached. DO NOT DISCHARGE!
     
    Power steering pump, with the lines attached
     
    Alternator
     
    Coolant bottle
     
    Heater hoses
     
    Accelerator and speed control cables
     
    Lower and upper radiator hoses
     
    Engine ground straps
     
    Intake Air Temperature (IAT) sensor
     
    Fuel injection wiring connectors
     
    Throttle Position (TP) sensor
     
    Idle Air Control (IAC) motor
     
    Oil pressure sender connector
     
    Engine Coolant Temperature (ECT) sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    Camshaft position sensor
     
    Ignition coil wiring connector
     
    Crankshaft Position (CKP) sensor
     
    Coil pack
     
    Fuel rail
     
    PCV hose
     
    Vacuum hoses from the intake manifold
     
    Knock sensor connectors
     
    Oil dipstick tube
     
    Intake manifold
     
    Heated Oxygen (HO 2 S) sensor connector
     
    Block heater connector
     
    Front driveshaft at the differential
     
    Starter
     
    Structural cover
     
    With a manual transmission, remove the transmission
     
    Torque converter bolts and matchmark the converter
     
    Automatic transmission-to-engine bolts
     
    Exhaust front pipes
     
    Left and right engine mounts
     

  10.  
  11. Place a support stand under the transmission.
  12.  
  13. Install an engine lift plate
  14.  
  15. Lift the engine out of the vehicle.
  16.  

To install:

  1. If equipped with a manual transmission, install the transmission
  2.  
  3. Lower the engine and install the mounts. Don-t tighten the bolts yet.
  4.  
  5. If equipped with an automatic transmission, perform the following steps:
    1. Align the torque converter housing to the engine.
    2.  
    3. Torque the bolts to 30 ft. lbs. (41 Nm).
    4.  

  6.  
  7. Install or connect the following:
    WARNING
    The structural cover must be held tightly against the engine and bellhousing during tightening. The torque for all bolts is 40 ft. lbs. (54 Nm); the bolts must be tightened in the order shown.



    Install the torque converter to flexplate bolts. Torque the bolts to 50 ft. lbs. (68 Nm)
     
    Torque the through bolts to 45 ft. lbs. (61 Nm)
     
    Engine ground strap
     
    Starter motor
     
    CKP sensor
     
    Block heater cable
     
    Structural cover
     



    Click image to see an enlarged view

    Fig. Tighten the structural cover bolts in this order-3.7L, 4.7L and 5.7L engines

    Tighten the structural cover bolts in this order-3.7L, 4.7L and 5.7L engines

    Exhaust pipes. New flange clamps MUST be used!
     
    HO 2 S sensor connectors
     
    KS sensors
     
    Intake Manifold
     
    Dipstick tube
     
    Vacuum hoses to the intake manifold
     
    PCV and breather hoses
     
    Fuel rail
     
    Ignition coil
     
    IAT sensor
     
    Fuel injector connectors
     
    TP sensor
     
    IAC motor
     
    Oil pressure sender
     
    ECT sensor electrical connector
     
    MAP sensor
     
    CMP sensor
     
    Radiator hoses
     
    Cruise control cable, if equipped
     
    Throttle cable
     
    Heater hoses
     
    Coolant bottle
     
    Power steering pump
     
    Alternator
     
    A/C compressor
     
    Radiator
     
    Fan assemblies
     
    Air cleaner assembly
     
    Negative battery cable
     

  8.  
  9. Fill and bleed the power steering system.
  10.  
  11. Fill the engine with clean oil.
  12.  
  13. Start the engine and check for leaks, repair if necessary.
  14.  

3.9L, 5.2L, 5.9L & 8.0L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:
    WARNING
    Do not lift the engine by the intake manifold. Damage to the manifold may result.



    Negative battery cable
     
    Hood
     
    Upper crossmember and top core support
     
    Radiator hoses
     
    Cooling fan and shroud
     
    Radiator
     
    Accelerator cable
     
    Cruise control cable, if equipped
     
    Transmission cable, if equipped
     
    Heater hoses
     
    Intake manifold vacuum lines
     
    Accessory drive belt
     
    Power steering pump
     
    A/C compressor, if equipped
     
    Engine control sensor harness connectors
     
    Engine block heater, if equipped
     
    Fuel line
     
    Exhaust front pipe
     
    Starter motor
     
    Torque converter, if equipped
     
    Transmission oil cooler lines, if equipped
     
    Engine mounts
     
    Transmission flange bolts. Support the transmission.
     
    Engine
     

  10.  

To install:

  1. Install or connect the following:

    Engine. Tighten the engine mount bolts to 70 ft. lbs. (95 Nm).
     
    Transmission flange bolts. Tighten the bolts to 40-45 ft. lbs. (54-61 Nm).
     
    Transmission oil cooler lines, if equipped
     
    Torque converter, if equipped. Tighten the bolts to 23 ft. lbs. (31 Nm).
     
    Starter motor
     
    Exhaust front pipe
     
    Fuel line
     
    Engine block heater, if equipped
     
    Engine control sensor harness connectors
     
    A/C compressor, if equipped
     
    Power steering pump
     
    Accessory drive belt
     
    Intake manifold vacuum lines
     
    Heater hoses
     
    Transmission cable, if equipped
     
    Cruise control cable, if equipped
     
    Accelerator cable
     
    Radiator
     
    Cooling fan and shroud
     
    Radiator hoses
     
    Upper crossmember and top core support
     
    Hood
     
    Negative battery cable
     

  2.  
  3. Fill the crankcase to the correct level.
  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

4.7L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system and engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Battery and tray
     
    Exhaust crossover pipe
     
    On 4wd, the axle vent tube
     
    Left and right engine mount through bolts
     
    On 4wd, the left and right engine mount bracket locknuts
     
    Ground straps
     
    CKP sensor
     
    On 4wd, the axle isolator bracket
     
    Structural cover
     
    Starter
     
    Torque converter bolts
     
    Transmission-to-engine bolts
     
    Engine block heater
     
    Resonator and air inlet
     
    Throttle and speed control cables
     
    Crankcase breathers
     
    A/C compressor
     
    Shroud and fan assemblies
     
    Transmission cooler lines
     
    Radiator hoses
     
    Radiator
     
    Alternator
     
    Heater hoses
     
    Engine harness
     
    Vacuum lines
     
    Fuel system pressure
     
    Fuel line at the rail
     
    Power steering pump
     

  6.  
  7. Install lifting eyes and take up the weight of the engine with a crane.
  8.  
  9. Support the transmission with a jack.
  10.  
  11. Remove the engine.
  12.  
  13. To install
  14.  
  15. Installation is the reverse of removal. Observe the following:
    WARNING
    The structural cover must be held tightly against the engine and bellhousing during tightening. The torque for all bolts is 40 ft. lbs. (54 Nm); the bolts must be tightened in the order shown.



    Left and right engine mount through bolts: 2wd 70 ft. lbs. (95 Nm); 4wd 75 ft. lbs. (102 Nm)
     
    On 4wd, the bracket locknuts: 30 ft. lbs. (41 Nm)
     
    Transmission-to-engine bolts: 30 ft. lbs. (41 Nm)
     

  16.  

5.7L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Air cleaner and resonator
     
    Accessory drive belt
     
    Engine fan
     
    Radiator
     
    Upper crossmember and top core support
     
    A/C compressor, if equipped
     
    Alternator
     
    Intake manifold and IAFM as an assembly
     
    Heater hoses
     
    Power steering pump
     
    Fuel line
     
    Engine front mount thru-bolt nuts
     
    Transmission oil cooler lines, if equipped
     
    Exhaust pipes at the manifolds
     
    Starter motor
     
    Structural dust cover and transmission inspection cover
     
    Torque converter-to-flexplate bolts
     
    Transmission flange bolts. Support the transmission.
     
    Engine
     

  10.  

To install:


WARNING
The structural cover must be held tightly against the engine and bellhousing during tightening. The torque for all bolts is 40 ft. lbs. (54 Nm); the bolts must be tightened in the order shown.

  1. Install or connect the following:

    Engine. Tighten the engine mount thru-bolt finger-tight.
     
    Transmission flange bolts. Tighten the bolts to 40-45 ft. lbs. (54-61 Nm). Then, tighten the mount bolt nuts to 70 ft. lbs. (95 Nm)
     
    Transmission oil cooler lines, if equipped
     
    Torque converter, if equipped. Tighten the bolts to 23 ft. lbs. (31 Nm).
     
    Structural dust cover and transmission inspection cover
     
    Starter motor
     
    Fuel line
     
    Power steering pump
     
    Heater hoses
     
    Intake manifold and IAFM as an assembly
     
    Alternator
     
    A/C compressor, if equipped
     
    Upper crossmember and top core support
     
    Radiator
     
    Engine fan
     
    Accessory drive belt
     
    Air cleaner and resonator
     
    Hood
     
    Negative battery cable
     

  2.  
  3. Fill the crankcase to the correct level.
  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

 
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