Complete removal and reinstallation of the 6.7L Cummins diesel engine from a 2014 Ram 2500 4WD, including disconnection of all systems, transmission separation, and engine extraction.

Warnings

Tools required

Parts

• Engine oil filter × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Engine coolant × 18 — Mopar OAT Purple
• Exhaust manifold gaskets × 1 — Use OEM specification
• Engine-to-transmission gasket/seal × 1 — Use OEM specification
• Various hose clamps (assorted) × 10 — Use OEM specification
• Anti-seize compound × 1 — High-temperature rated
• Thread locker (medium strength) × 1 — Loctite 243 or equivalent

Fluids

• Mopar 5W-20 Synthetic Blend Engine Oil — 13 qt
• Mopar OAT Coolant (Purple) — 18 qt

Preparation

1. Position vehicle on level surface and engage parking brake
2. Disconnect both battery cables (negative first, then positive) and remove batteries
3. Remove hood by unbolting hinges with assistant support
4. Place fender covers to protect painted surfaces
5. Raise vehicle on lift or jack stands to working height for underside access
6. Remove engine skid plate and belly pan if equipped
7. Drain engine oil completely and remove oil filter
8. Drain cooling system at radiator petcock and lower hose into appropriate containers
9. Relieve fuel system pressure by removing fuel pump relay and cranking engine briefly
10. Remove radiator upper fan shroud and cooling fan assembly
11. Label all electrical connectors, vacuum lines, and hoses with tape or tags before disconnection

Procedure

1. 1

   Remove intake and air system components
   Remove air filter housing and intake tubing. Disconnect intercooler boots and remove intercooler piping. Remove intake grid heater wiring if equipped. Disconnect turbocharger inlet piping. Remove intake manifold cover and disconnect all intake manifold sensors and wiring.
   Torque spec

   Cover Bolts22 Nm (16 lb-ft)
2. 2

   Disconnect fuel system
   Using appropriate diesel fuel line disconnect tools, disconnect high-pressure fuel lines at injection pump and fuel rail. Cap all open fuel ports immediately. Disconnect fuel return lines. Remove fuel filter housing if it interferes with engine removal. Disconnect fuel heater electrical connections.
   ⚠Diesel fuel will drain from disconnected lines. Have absorbent materials ready and dispose of properly.
3. 3

   Remove exhaust system components
   From underneath vehicle, unbolt exhaust downpipe from turbocharger outlet. Support exhaust system and remove exhaust manifold to allow clearance if needed. If removing manifold, work from hot side (center) to cold side (ends) when loosening nuts. Apply penetrating oil to exhaust fasteners before removal.
   ℹ️Exhaust studs are prone to breaking. Apply penetrating oil and allow to soak. Heat may be required for removal.
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
4. 4

   Disconnect cooling system
   Remove radiator upper and lower hoses from engine. Disconnect heater hoses at firewall connections. Remove coolant bypass hoses. Disconnect coolant temperature sensors and mark locations. If radiator interferes with engine removal, unbolt and remove radiator assembly completely.
   ⚠Residual coolant will remain in engine block. Keep drain pans positioned during removal.
5. 5

   Remove accessory drive components
   Using serpentine belt tool, remove drive belt and set aside. Unbolt and remove AC compressor without disconnecting refrigerant lines; secure to frame with wire or bungee cords away from engine. Remove power steering pump and secure similarly. Unbolt alternator and set aside. Disconnect all electrical connections from these components first.
   Torque spec

   AC Compressor Bolts25 Nm (18 lb-ft)

   Alternator Mounting Bolts50 Nm (37 lb-ft)

   Power Steering Pump Bolts25 Nm (18 lb-ft)
6. 6

   Disconnect electrical and control systems
   Disconnect engine wiring harness at main connectors near firewall. Remove starter motor and secure away from work area. Disconnect all remaining sensors including oil pressure, crankshaft position, camshaft position, and intake air temperature sensors. Disconnect throttle position sensor and any remaining electronic controls. Disconnect grid heater relay and wiring.
   Torque spec

   Mounting Bolts64 Nm (47 lb-ft)

   Sensor Bolts15 Nm (11 lb-ft)
7. 7

   Separate transmission from engine
   Support transmission with transmission jack positioned securely under transmission pan. Remove transmission crossmember if needed for clearance. Working from underneath and through bellhousing access, remove all transmission-to-engine bolts. Note bolt lengths and locations as they vary. Carefully separate transmission from engine by prying at alignment dowel locations. Keep transmission supported and level as it separates from engine. Lower transmission slightly and secure on jack.
   ⚠️Ensure transmission jack is secure and transmission is balanced before separating. Transmission can shift suddenly when separation occurs.
   Torque spec

   Transmission-to-Engine Bolts55 Nm (41 lb-ft)
8. 8

   Remove engine mounts
   Support engine weight with engine hoist attached to factory lifting eyes on cylinder head. Apply slight upward tension to unload engine mounts. Remove engine mount-to-frame bolts on both sides. Remove engine mount-to-block bolts. Verify all connections are disconnected before proceeding with removal.
   ⚠Verify engine hoist is securely attached to lifting eyes and rated for engine weight before unbolting mounts.
   Torque spec

   Engine Mount-to-Frame Bolts75 Nm (55 lb-ft)

   Engine Mount-to-Block Bolts65 Nm (48 lb-ft)
9. 9

   Extract engine from vehicle
   With engine hoist supporting full engine weight and engine leveler attached, perform final visual inspection to ensure all connections are disconnected. Slowly raise engine while tilting front slightly upward using leveler. Guide engine forward and upward, clearing transmission input shaft, radiator support, and frame rails. Have assistant guide engine to prevent contact with body panels. Once clear of vehicle, lower onto engine stand or secure work surface.
   ⚠️Move engine slowly and deliberately. Watch clearances at all times. Do not allow engine to swing freely on hoist.
   ℹ️Engine may need to be rotated or angled during extraction. Use leveler to adjust angle as needed for clearance.
10. 10

    Prepare engine for reinstallation
    With engine on stand, inspect and replace all necessary gaskets, seals, and wear items. Clean mating surfaces on engine block and transmission bellhousing. Apply anti-seize to exhaust manifold studs. Install new engine oil drain plug crush washer. If flywheel was removed, clean flywheel and crankshaft flange surfaces thoroughly, apply thread locker to flywheel bolts, and torque in star pattern. Inspect and replace pilot bearing/bushing if applicable.
    ℹ️Flywheel bolts are often TTY (torque-to-yield). Check service manual to determine if bolts must be replaced.
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)

    Oil Drain Plug35 Nm (26 lb-ft)
11. 11

    Install engine into vehicle
    Reverse extraction process. Attach engine to hoist at lifting eyes and adjust leveler angle to match removal angle. Carefully lower engine into engine bay, angling to clear frame rails and radiator support. Guide engine rearward, aligning with transmission input shaft and bellhousing dowels. Use pry bar if needed to align dowels, but do not force. Once aligned, guide engine fully into position with bellhousing seated against block.
    ⚠Do not allow engine weight to hang on transmission input shaft. Engine must be supported until bellhousing is fully engaged.
12. 12

    Install engine mounts and mate transmission
    Install engine mount-to-block bolts and torque to specification. Install engine mount-to-frame bolts and torque to specification. Install all transmission-to-engine bolts, starting with top bolts first and working down, torquing in cross pattern. Install transmission crossmember if removed. Remove transmission jack and engine hoist once all mount bolts are torqued.
    Torque spec

    Engine Mount-to-Block Bolts65 Nm (48 lb-ft)

    Engine Mount-to-Frame Bolts75 Nm (55 lb-ft)

    Transmission-to-Engine Bolts55 Nm (41 lb-ft)
13. 13

    Reinstall accessory components
    Reinstall alternator and torque mounting bolts. Reinstall power steering pump and torque bolts. Reinstall AC compressor and torque bolts. Install serpentine belt following routing diagram on fan shroud. Reconnect all electrical connections to accessories. Install starter motor and torque mounting bolts.
    Torque spec

    Alternator Mounting Bolts50 Nm (37 lb-ft)

    Power Steering Pump Bolts25 Nm (18 lb-ft)

    AC Compressor Bolts25 Nm (18 lb-ft)

    Mounting Bolts64 Nm (47 lb-ft)
14. 14

    Reconnect all engine systems
    Reconnect engine wiring harness at main connectors. Reconnect all sensors in reverse order of removal using labels for reference. Reconnect fuel supply and return lines, ensuring connections are fully seated and locked. Reconnect cooling system hoses with new clamps if needed. Install radiator if removed. Install exhaust system, applying anti-seize to manifold studs and torquing nuts from center outward. Reconnect intake system and intercooler piping.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)

    Sensor Bolts15 Nm (11 lb-ft)
15. 15

    Fill fluids and perform initial startup
    Install new engine oil filter. Fill engine with 13 quarts of Mopar 5W-20 synthetic blend oil. Fill cooling system with 18 quarts Mopar OAT purple coolant, bleeding air from system per service manual procedure. Reinstall batteries and reconnect battery cables (positive first, then negative). Install hood with assistant. Prime fuel system by cycling ignition key without cranking several times. Check for fuel leaks at all connections. Perform initial start and monitor for leaks, unusual noises, or warning lights. Allow engine to reach operating temperature and recheck fluid levels.
    ⚠Do not rev engine during initial startup. Allow to idle and warm gradually while monitoring gauges and checking for leaks.
    ℹ️Engine may produce some smoke initially from assembly lubricants and residues. This should clear after a few minutes of operation.

Reassembly

1. Torque all fasteners to specifications using calibrated torque wrench
2. Double-check all electrical connections are secure and properly seated
3. Verify all fluid levels are correct after initial warm-up cycle
4. Bleed cooling system completely to remove all air pockets
5. Check serpentine belt tension and alignment after installation
6. Verify no tools or parts are left in engine bay before final startup
7. Install engine skid plate and belly pan after confirming no leaks

Verification

• Start engine and verify oil pressure rises within 5 seconds on gauge
• Check for fuel leaks at all connection points with engine running
• Check for coolant leaks at hoses, thermostat housing, and water pump
• Check for oil leaks at pan, filter, and rear main seal
• Verify all gauges read normal operating values
• Check for exhaust leaks at manifold and downpipe connections
• Verify AC compressor, alternator, and power steering pump operate normally
• Test drive vehicle to verify normal operation under load
• Recheck all fluid levels after test drive when engine is warm
• Scan for diagnostic trouble codes and clear if installation-related codes are present

More procedures for this vehicle