Ram Truck 1500, 2500 & 3500 (2006-2008)

Engine

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Removal & Installation



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



    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.  

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.  

5.9L & 6.7L Diesel Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect both battery negative cables.
  4.  
  5. Disconnect engine grid heater harness at grid heater relays.
  6.  
  7. Disconnect the electrical connections from rear of alternator.
  8.  
  9. Recover the A/C refrigerant.
  10.  
  11. Raise the vehicle on a hoist.
  12.  
  13. Drain engine coolant.
  14.  
  15. Remove engine oil drain plug and drain engine oil. Reinstall drain plug.
  16.  
  17. Lower the vehicle.
  18.  
  19. Remove fan and fan drive.
  20.  
  21. Remove fan shroud mounting bracket and shroud.
  22.  
  23. Remove the radiator upper hose.
  24.  
  25. Disconnect the coolant recovery bottle hose from the radiator fill neck.
  26.  
  27. Disconnect heater core supply and return hoses from the cylinder head fitting and coolant pipe.
  28.  
  29. Raise the vehicle on a hoist.
  30.  
  31. Remove transmission and transfer case (if equipped).
  32.  
  33. Disconnect exhaust pipe from turbocharger extension pipe.
  34.  
  35. Disconnect engine harness to vehicle harness connectors.
  36.  
  37. Remove the starter motor.
  38.  
  39. Remove the flywheel/flexplate.
  40.  
  41. Remove the transmission adapter. (If equipped).
  42.  
  43. Disconnect A/C suction/discharge hose from the rear of the A/C compressor.
  44.  
  45. Lower the vehicle.
  46.  
  47. Disconnect lower radiator hose from radiator outlet.
  48.  
  49. For automatic transmission models, disconnect transmission oil cooler lines from in front of radiator using special tool 6931
  50.  
  51. Remove the radiator.
  52.  
  53. If A/C equipped, disconnect A/C condenser refrigerant lines.
  54.  
  55. Disconnect charge air cooler piping.
  56.  
  57. Remove charge air cooler mounting bolts.
  58.  
  59. Remove charge air cooler from vehicle.
  60.  
  61. Remove the A/C condenser.
  62.  
  63. Remove damper and speed indicator ring from front of engine.
  64.  
  65. Remove the lower fan shroud bracket from engine.
  66.  
  67. Remove upper fan shroud brackets from engine
  68.  
  69. Disconnect engine block heater connector
  70.  
  71. Disconnect A/C compressor and pressure sensor electrical connectors.
  72.  
  73. Remove the passenger battery ground cable from the engine block. Remove the driver side battery ground cable from the engine block.
  74.  
  75. Remove power steering pump from engine by removing 3 bolts.
  76.  
  77. Disconnect the ECM power connector.
  78.  
  79. Disconnect the ECM ground wire from the hydro form screw.
  80.  
  81. Disconnect the fuel supply and return hoses.
  82.  
  83. Remove the cylinder head cover.
  84.  
  85. Disconnect the wire harnesses from the injectors.
  86.  
  87. Remove the cylinder head cover carrier gasket
    NOTE
    Extreme care should be used to keep dirt/debris from entering the fuel lines. Plastic caps should be used on the ends of the fuel lines.

  88.  
  89. Loosen number 6 fuel line shield bolts and rotate shield out of the way.
  90.  
  91. Remove cylinder number 5 and number 6 high pressure fuel lines.
  92.  
  93. Remove the rear engine lift bracket.
  94.  
  95. Remove cylinder number 4, number 5, and number 6 intake and exhaust rocker arms, pedestals, and push tubes. (Note the original location for reassembly).
  96.  
  97. Remove the fuel connector tube nut and fuel connector tube. Remove cylinder number 5 and number 6 fuel injector.
  98.  
  99. Remove rocker housing.
  100.  
  101. Remove two cylinder head bolts and install tool number 9009. Tighten bolts to 77 ft. lbs. (105 Nm).
  102.  
  103. Loosen but do not remove engine mount through bolts and nuts.
  104.  
  105. Disconnect hood support struts and position hood out of the way.
  106.  
  107. Attach a chain with two hooks to the engine lift brackets.
  108.  
  109. While keeping engine level, lift straight up out of the mounts.
  110.  
  111. Rotate nose of the engine upward and pull out of the chassis.
  112.  

To install:

  1. Remove cylinder head bolts. Install special tool 9009. Tighten bolts to 77 ft. lbs. (105 Nm).
  2.  
  3. Lower engine into the engine compartment and install the engine mount through bolts and nuts.
  4.  
  5. Tighten the mount through bolts and nuts to 65 ft. lbs. (88 Nm).
  6.  
  7. Remove the engine lifting device tool 9009.
  8.  
  9. Check cylinder head cap screw length and install into cylinder head.
  10.  
  11. Tighten in 4 steps as follows:

    Step 1: Tighten to 52 ft. lbs. (70 Nm)
     
    Step 2: Back off 360 degrees
     
    Step 3: Tighten to 77 ft. lbs. (105 Nm)
     
    Step 4: Rotate 90 degrees
     

  12.  
  13. Install rocker housing. Torque to 18 ft. lbs. (24 Nm).
  14.  
  15. Replace injector o-ring and sealing washer on injector-s number 5 and number 6.
  16.  
  17. Install injectors and tighten using the following steps:

    Install injector hold-down cap screws and torque to 44 in. lbs. (5 Nm).
     
    Loosen injector hold-down cap screws
     
    Install HPC connector tube and nut. Tighten nut to 11 ft. lbs. (15 Nm).
     
    Tighten the injector hold-down cap screws to 89 in. lbs. (10 Nm).
     
    Tighten the HPC connector tube nut to 37 ft. lbs. (50 Nm).
     

  18.  
  19. Install rear engine lift bracket. Tighten to 57 ft. lbs. (77 Nm).
  20.  
  21. Install number 5 and number 6 high pressure fuel lines.
  22.  
  23. Tighten fuel line fittings to 22 ft. lbs. (30 Nm). Tighten brace cap screw and nut to 18 ft. lbs. (24 Nm).
  24.  
  25. Install push tubes, rocker arms, and pedestals for cylinders number 4, number 5, and number 6. Tighten the mounting bolts to 27 ft. lbs. (36 Nm).
  26.  
  27. Reset valve lash on cylinders number 4, number 5, and number 6. Tighten adjusting nuts to 18 ft. lbs. (24 Nm)
  28.  
  29. Install the injector wiring/gasket.
  30.  
  31. Install cylinder head cover carrier gasket
  32.  
  33. Connect the injector harness nuts to injectors. Tighten to 11 in. lbs (1.25 Nm).
  34.  
  35. Connect the injector wiring harness connectors to injector connections on cylinder head cover carrier gasket.
  36.  
  37. Install cylinder head cover
  38.  
  39. Connect breather tube and lube oil drain tube to cylinder head cover
  40.  
  41. Connect fuel supply and return hoses.
  42.  
  43. Connect ECM ground to hydro form screw. Connect ECM power connector.
  44.  
  45. Install the power steering pump.
  46.  
  47. Install the damper and speed indicator ring. Tighten to 30 ft. lbs. (40 Nm) plus 60 degrees.
  48.  
  49. Install the lower fan shroud bracket. Tighten to 18 ft. lbs. (24 Nm).
  50.  
  51. Install upper fan shroud brackets, but do not tighten fasteners at this time.
  52.  
  53. Connect the engine block heater connection.
  54.  
  55. Connect the A/C compressor and pressure sensor connectors
  56.  
  57. Install the charge air cooler. Install and tighten the charge air cooler mounting bolts to 17 in. lbs. (2 Nm).
  58.  
  59. Connect the charge air cooler tubes. Tighten all clamps to 72 in. lbs. (8 Nm).
  60.  
  61. Install the a/c condenser.
  62.  
  63. Connect the a/c refrigerant lines to the a/c condenser.
  64.  
  65. Install the radiator upper support panel.
  66.  
  67. Install the radiator.
  68.  
  69. Connect the transmission quick-connect oil cooler lines.
  70.  
  71. Raise the vehicle.
  72.  
  73. Connect A/C compressor suction/discharge hose (if equipped).
  74.  
  75. Install the radiator lower hose and clamps.
  76.  
  77. Install the battery negative cables to the engine block on the driver and passenger side.
  78.  
  79. Install the transmission adapter with a new camshaft rectangular ring seal. Tighten to 57 ft. lbs. (77 Nm).
  80.  
  81. Install the flywheel and adapter or flexplate. Tighten to 101 ft. lbs. (137 Nm).
    NOTE
    If the engine is equipped with a flexplate or crankshaft adapter, a new clamp ring must be used. If the engine has a flywheel with washers, the washers can be reused.

  82.  
  83. Install the starter motor and tighten to 32 ft. lbs. (43 Nm).
  84.  
  85. Connect engine to vehicle harness connectors.
  86.  
  87. Install transmission and transfer case (if equipped).
  88.  
  89. Connect the exhaust pipe to the turbocharger elbow.
  90.  
  91. Connect the transmission auxiliary oil cooler lines (if equipped).
  92.  
  93. Lower the vehicle.
  94.  
  95. Connect the heater core supply and return hoses.
  96.  
  97. Fill the crankcase to the correct level.
  98.  
  99. Fill the cooling system.
  100.  
  101. Vacuum and recharge the A/C system (if equipped).
  102.  
  103. Start the engine and check for leaks.
  104.  

 
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