5.9L & 6.7L DIESEL ENGINE removal on Dodge Truck?

The Dodge Truck RAM diesel engine replacing.

The Engine removal/install guide for dodge truck.

The step by step procedure  is as follows:----

5.9L & 6.7L Diesel Engines

  1. Disconnect both battery negative cables.
  2. Disconnect engine grid heater harness at grid heater relays.
  3. Disconnect the electrical connections from rear of alternator.
  4. Recover the A/C refrigerant.
  5. Raise the vehicle on a hoist.
  6. Drain engine coolant.
  7. Remove engine oil drain plug and drain engine oil. Reinstall drain plug.
  8. Lower the vehicle.
  9. Remove fan and fan drive.
  10. Remove fan shroud mounting bracket and shroud.
  11. Remove the radiator upper hose.
  12. Disconnect the coolant recovery bottle hose from the radiator fill neck.
  13. Disconnect heater core supply and return hoses from the cylinder head fitting and coolant pipe.
  14. Raise the vehicle on a hoist.
  15. Remove transmission and transfer case (if equipped).
  16. Disconnect exhaust pipe from turbocharger extension pipe.
  17. Disconnect engine harness to vehicle harness connectors.
  18. Remove the starter motor.
  19. Remove the flywheel/flexplate.
  20. Remove the transmission adapter. (If equipped).
  21. Disconnect A/C suction/discharge hose from the rear of the A/C compressor.
  22. Lower the vehicle.
  23. Disconnect lower radiator hose from radiator outlet.
  24. For automatic transmission models, disconnect transmission oil cooler lines from in front of radiator using special tool 6931
  25. Remove the radiator.
  26. If A/C equipped, disconnect A/C condenser refrigerant lines.
  27. Disconnect charge air cooler piping.
  28. Remove charge air cooler mounting bolts.
  29. Remove charge air cooler from vehicle.
  30. Remove the A/C condenser.
  31. Remove damper and speed indicator ring from front of engine.
  32. Remove the lower fan shroud bracket from engine.
  33. Remove upper fan shroud brackets from engine
  34. Disconnect engine block heater connector
  35. Disconnect A/C compressor and pressure sensor electrical connectors.
  36. Remove the passenger battery ground cable from the engine block. Remove the driver side battery ground cable from the engine block.
  37. Remove power steering pump from engine by removing 3 bolts.
  38. Disconnect the ECM power connector.
  39. Disconnect the ECM ground wire from the hydro form screw.
  40. Disconnect the fuel supply and return hoses.
  41. Remove the cylinder head cover.
  42. Disconnect the wire harnesses from the injectors.
  43. Remove the cylinder head cover carrier gasket
    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.
  44. Loosen number 6 fuel line shield bolts and rotate shield out of the way.
  45. Remove cylinder number 5 and number 6 high pressure fuel lines.
  46. Remove the rear engine lift bracket.
  47. Remove cylinder number 4, number 5, and number 6 intake and exhaust rocker arms, pedestals, and push tubes. (Note the original location for reassembly).
  48. Remove the fuel connector tube nut and fuel connector tube. Remove cylinder number 5 and number 6 fuel injector.
  49. Remove rocker housing.
  50. Remove two cylinder head bolts and install tool number 9009. Tighten bolts to 77 ft. lbs. (105 Nm).
  51. Loosen but do not remove engine mount through bolts and nuts.
  52. Disconnect hood support struts and position hood out of the way.
  53. Attach a chain with two hooks to the engine lift brackets.
  54. While keeping engine level, lift straight up out of the mounts.
  55. Rotate nose of the engine upward and pull out of the chassis.
To install:
  1. Remove cylinder head bolts. Install special tool 9009. Tighten bolts to 77 ft. lbs. (105 Nm).
  2. Lower engine into the engine compartment and install the engine mount through bolts and nuts.
  3. Tighten the mount through bolts and nuts to 65 ft. lbs. (88 Nm).
  4. Remove the engine lifting device tool 9009.
  5. Check cylinder head cap screw length and install into cylinder head.
  6. 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
  7. Install rocker housing. Torque to 18 ft. lbs. (24 Nm).
  8. Replace injector o-ring and sealing washer on injector-s number 5 and number 6.
  9. 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).
  10. Install rear engine lift bracket. Tighten to 57 ft. lbs. (77 Nm).
  11. Install number 5 and number 6 high pressure fuel lines.
  12. Tighten fuel line fittings to 22 ft. lbs. (30 Nm). Tighten brace cap screw and nut to 18 ft. lbs. (24 Nm).
  13. 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).
  14. Reset valve lash on cylinders number 4, number 5, and number 6. Tighten adjusting nuts to 18 ft. lbs. (24 Nm)
  15. Install the injector wiring/gasket.
  16. Install cylinder head cover carrier gasket
  17. Connect the injector harness nuts to injectors. Tighten to 11 in. lbs (1.25 Nm).
  18. Connect the injector wiring harness connectors to injector connections on cylinder head cover carrier gasket.
  19. Install cylinder head cover
  20. Connect breather tube and lube oil drain tube to cylinder head cover
  21. Connect fuel supply and return hoses.
  22. Connect ECM ground to hydro form screw. Connect ECM power connector.
  23. Install the power steering pump.
  24. Install the damper and speed indicator ring. Tighten to 30 ft. lbs. (40 Nm) plus 60 degrees.
  25. Install the lower fan shroud bracket. Tighten to 18 ft. lbs. (24 Nm).
  26. Install upper fan shroud brackets, but do not tighten fasteners at this time.
  27. Connect the engine block heater connection.
  28. Connect the A/C compressor and pressure sensor connectors
  29. Install the charge air cooler. Install and tighten the charge air cooler mounting bolts to 17 in. lbs. (2 Nm).
  30. Connect the charge air cooler tubes. Tighten all clamps to 72 in. lbs. (8 Nm).
  31. Install the a/c condenser.
  32. Connect the a/c refrigerant lines to the a/c condenser.
  33. Install the radiator upper support panel.
  34. Install the radiator.
  35. Connect the transmission quick-connect oil cooler lines.
  36. Raise the vehicle.
  37. Connect A/C compressor suction/discharge hose (if equipped).
  38. Install the radiator lower hose and clamps.
  39. Install the battery negative cables to the engine block on the driver and passenger side.
  40. Install the transmission adapter with a new camshaft rectangular ring seal. Tighten to 57 ft. lbs. (77 Nm).
  41. Install the flywheel and adapter or flexplate. Tighten to 101 ft. lbs. (137 Nm).
    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.
  42. Install the starter motor and tighten to 32 ft. lbs. (43 Nm).
  43. Connect engine to vehicle harness connectors.
  44. Install transmission and transfer case (if equipped).
  45. Connect the exhaust pipe to the turbocharger elbow.
  46. Connect the transmission auxiliary oil cooler lines (if equipped).
  47. Lower the vehicle.
  48. Connect the heater core supply and return hoses.
  49. Fill the crankcase to the correct level.
  50. Fill the cooling system.
  51. Vacuum and recharge the A/C system (if equipped).
  52. Start the engine and check for leaks.

These details will help.


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