Complete replacement of the long block assembly on a 2014 Ram 2500 with 6.7L Cummins diesel engine, including removal of all external components, engine extraction, installation of new long block, and reassembly of all systems.

Warnings

Tools required

Parts

• Long block assembly (6.7L Cummins remanufactured) × 1 — Use OEM specification
• Engine oil filter × 1 — Mopar 68157291AA or equivalent
• Fuel filter/water separator × 1 — Mopar 68197867AA
• Valve cover gasket set × 1 — Use OEM specification
• Exhaust manifold gaskets × 1 — Use OEM specification
• Intake manifold gaskets × 1 — Use OEM specification
• Turbocharger mounting gaskets × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Serpentine belt × 1 — Use OEM specification
• Coolant hoses (as needed) × 1 — Inspect and replace worn hoses
• Engine mount hardware × 1 — Use OEM specification
• Anti-seize compound × 1 — High temperature rated

Fluids

• Mopar 5W-20 Synthetic Blend Engine Oil — 13 qt
• Mopar OAT Coolant (Purple) — 18 qt
• Mopar ATF+4 — 10 qt

Preparation

1. Park vehicle on level surface with adequate overhead clearance for engine hoist. Engage parking brake and chock rear wheels.
2. Disconnect both battery cables (negative first, then positive) and remove battery.
3. Remove hood after marking hinge positions for reinstallation alignment.
4. Drain engine coolant completely from radiator and block drain plugs into appropriate container.
5. Drain engine oil and remove oil filter.
6. Have air conditioning system professionally evacuated and recover refrigerant.
7. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls.
8. Place drain pans under vehicle for residual fluid capture.
9. Take detailed photographs of engine bay from multiple angles for reference during reassembly.

Procedure

1. 1

   Remove front accessories and cooling system
   Remove radiator shroud, radiator, intercooler, charge air cooler, and all cooling hoses. Disconnect transmission cooler lines from radiator. Remove serpentine belt and tensioner. Remove cooling fan assembly (viscous or electric depending on configuration). Disconnect all coolant hoses from engine including heater hoses. Cap all open lines to prevent contamination.
2. 2

   Disconnect air intake and exhaust systems
   Remove complete air intake system from air filter housing to turbocharger inlet, including intake tube and resonator. Disconnect exhaust system at turbocharger outlet flange (may require cutting if rusted). Remove exhaust gas recirculation (EGR) cooler and all associated piping. Disconnect EGR valve and all vacuum lines. Remove diesel particulate filter (DPF) pressure sensor lines.
3. 3

   Remove turbocharger and exhaust manifold
   Disconnect turbocharger oil supply and drain lines. Remove turbocharger mounting hardware and carefully remove turbocharger assembly (weighs approximately 40 lbs). Apply penetrating oil to exhaust manifold nuts and allow to soak. Remove exhaust manifold nuts working from hot side (center) to cold side (ends) to minimize warping risk. Remove exhaust manifold and inspect for cracks.
   ⚠Exhaust manifold studs are prone to breaking on high-mileage engines. Have stud extractor set available if studs break during removal.
4. 4

   Disconnect fuel system
   Using proper line wrenches, disconnect high-pressure fuel lines from fuel rail to injection pump. Cap all open fuel lines immediately to prevent contamination. Disconnect fuel supply and return lines from fuel filter housing. Remove fuel filter housing assembly. Disconnect electrical connectors from all six fuel injectors and from injection pump. Label each connector for proper reinstallation.
   ⚠️Even with system depressurized, residual pressure may exist. Use caution when cracking fuel line fittings and keep face away from connections.
5. 5

   Disconnect electrical systems
   Disconnect and label all electrical connectors including: crankshaft position sensor, camshaft position sensor, oil pressure sensor, coolant temperature sensors, MAP sensor, IAT sensor, throttle position sensor, grid heater relay, glow plug controller, alternator connections, and starter connections. Remove engine harness from all mounting clips and position aside. Remove alternator and bracket assembly.
6. 6

   Remove intake manifold and valve cover
   Remove intake manifold bolts in reverse of tightening sequence (outside to inside pattern). Carefully lift intake manifold and gasket away from cylinder head. Remove valve cover bolts in reverse sequence and remove valve cover. Inspect valve train components if long block does not include cylinder head assembly.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)

   Cover Bolts22 Nm (16 lb-ft)
7. 7

   Disconnect transmission
   Support transmission with transmission jack. Remove transmission-to-engine mounting bolts (accessible from underneath and from sides). Remove flexplate/flywheel inspection cover. Remove torque converter-to-flexplate bolts (rotate crankshaft to access all bolts). Mark flexplate and torque converter orientation. Carefully separate transmission from engine by sliding straight back. Lower transmission slightly and support securely.
   ⚠Transmission weighs approximately 250 lbs when full of fluid. Ensure transmission jack is properly rated and positioned.
   Torque spec

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

   Remove engine mounts and accessories
   Remove power steering pump and bracket assembly without disconnecting hoses (secure aside). Remove air conditioning compressor mounting bolts and secure compressor aside without disconnecting refrigerant lines. Remove engine mount-to-frame mounting bolts on both sides. Remove front engine mount hardware. Verify all connections, lines, and hoses are disconnected from engine.
   Torque spec

   Mounting Bolts64 Nm (47 lb-ft)
9. 9

   Extract engine from vehicle
   Attach engine hoist chains to factory lifting eyes on engine block (front and rear). Use engine leveler to balance engine angle. Slowly raise engine while monitoring for any remaining connections. Tilt engine as needed to clear transmission input shaft and firewall. Once clear of transmission, continue lifting and tilting forward to clear radiator support. Move engine hoist forward and away from vehicle. Lower engine onto engine stand or suitable work surface.
   ⚠️Never work under suspended engine. Ensure hoist chains are properly rated and securely attached before lifting.
10. 10

    Transfer external components to new long block
    Verify which components are included with new long block. Transfer the following from old engine as needed: oil pan (with new gasket), timing cover (with new gasket), oil pump, oil filter adapter, water pump, thermostat housing, fuel injection pump, fuel rail, fuel injectors, EGR components, sensors (crankshaft position, camshaft position, oil pressure, coolant temperature), dipstick tube, and any brackets or bosses specific to your vehicle. Install new valve cover gasket.
    ℹ️Clean all mating surfaces thoroughly with non-abrasive cleaner. Do not use metal scrapers on aluminum surfaces.
    Torque spec

    Oil Pan Bolts12 Nm (9 lb-ft)

    Cover Bolts22 Nm (16 lb-ft)

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

    Install intake and exhaust manifolds on new engine
    Install new intake manifold gaskets on cylinder head. Position intake manifold and install bolts finger-tight. Torque intake manifold bolts in sequence from center outward. Apply anti-seize compound to exhaust manifold studs. Install new exhaust manifold gaskets. Install exhaust manifold and torque nuts working from center (hot side) to outer ends (cold side) in specified sequence.
    ℹ️Use only high-temperature nickel-based anti-seize on exhaust components. Standard anti-seize will burn off.
    Torque spec

    Intake Manifold Bolts25 Nm (18 lb-ft)

    Exhaust Manifold Nuts30 Nm (22 lb-ft)
12. 12

    Install new long block into vehicle
    Attach engine to hoist using lifting eyes. Carefully maneuver engine into engine bay, tilting as needed to clear radiator support and firewall. Align engine with transmission bell housing while lowering. Use engine leveler to adjust angle for proper transmission input shaft alignment. Guide engine onto transmission, ensuring torque converter pilot engages properly. Continue lowering until engine mounts align with frame brackets.
    ⚠Do not force engine into position. Misalignment can damage transmission input shaft or torque converter pilot.
13. 13

    Install engine mounts and reconnect transmission
    Install engine mount brackets and torque mounting bolts to specification. Install transmission-to-engine mounting bolts and torque in star pattern. Rotate crankshaft and align torque converter-to-flexplate marks made during disassembly. Install torque converter bolts and torque to specification. Install flexplate inspection cover. Remove transmission jack and engine hoist.
    Torque spec

    Mounting Bolts64 Nm (47 lb-ft)

    Transmission-to-Engine Bolts55 Nm (41 lb-ft)
14. 14

    Reinstall turbocharger and accessories
    Install new turbocharger gasket on exhaust manifold. Install turbocharger assembly and torque mounting hardware. Connect turbocharger oil supply and drain lines with new gaskets/seals. Install alternator and bracket assembly. Install power steering pump and bracket. Install air conditioning compressor. Install serpentine belt tensioner and new serpentine belt.
15. 15

    Reconnect fuel, electrical, and cooling systems
    Reconnect all electrical connectors using labels and photographs for reference. Reconnect fuel supply and return lines to filter housing. Install new fuel filter. Connect high-pressure fuel lines from injection pump to fuel rail using new sealing washers. Install all coolant hoses with new clamps as needed. Install radiator, intercooler, charge air cooler, and cooling fan assembly. Reconnect transmission cooler lines. Reconnect EGR system components and all vacuum lines. Reconnect air intake system from air filter to turbocharger inlet. Reconnect exhaust system at turbocharger outlet with new gasket.
16. 16

    Fill fluids and complete final assembly
    Install new oil filter. Install oil drain plug with new crush washer and torque to specification. Fill engine with 13 quarts of Mopar 5W-20 synthetic blend engine oil. Fill cooling system with 18 quarts of Mopar OAT Purple coolant through radiator cap and overflow reservoir. Check transmission fluid level and add Mopar ATF+4 as needed (approximately 10 quarts if drained). Reinstall battery and connect positive cable first, then negative cable. Install hood using alignment marks.
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)
17. 17

    Prime fuel system and perform initial start
    Turn ignition to ON position (without starting) for 30 seconds to allow fuel pump to prime system. Repeat 3-4 times. Crank engine for no more than 15 seconds at a time with 30 second rest between attempts. Engine should start within 2-3 cranking cycles. Once started, monitor for fuel leaks, oil leaks, and coolant leaks. Allow engine to idle and warm to operating temperature. Monitor oil pressure gauge (should read 10+ PSI at idle when warm).
    ⚠Do not crank engine continuously for more than 15 seconds. Excessive cranking can damage starter motor.
18. 18

    Recharge air conditioning and bleed cooling system
    Have air conditioning system evacuated, leak tested, and recharged by certified technician to proper refrigerant specification. Bleed cooling system by running engine to operating temperature with radiator cap removed (when safe to do so). Add coolant as level drops. Squeeze upper radiator hose to help purge air pockets. Install radiator cap and run engine through several heat cycles. Recheck coolant level when cold.

Reassembly

1. Verify all torque specifications were followed, especially TTY bolts which require torque-plus-angle method
2. Double-check that all electrical connectors are properly seated and locked
3. Inspect for any tools or parts left in engine bay before closing hood
4. Verify serpentine belt is properly routed and tensioned
5. Check all fluid levels including engine oil, coolant, transmission, power steering, and brake fluid

Verification

• Start engine and verify oil pressure reads at least 10 PSI at idle when warm (normal is 15-30 PSI)
• Check for fuel, oil, coolant, and exhaust leaks while engine is running
• Verify cooling fans operate properly and engine reaches normal operating temperature (180-210°F)
• Test drive vehicle and verify proper engine performance, smooth acceleration, and no abnormal noises
• Monitor for check engine lights or diagnostic trouble codes using scan tool
• Recheck all fluid levels after test drive and top off as necessary
• Perform ECM relearn procedure if required (some vehicles require idle relearn after major engine work)
• Change engine oil and filter after first 500 miles of operation on new long block
• Retorque cylinder head bolts after first heat cycle if accessible (verify service manual requirements)

More procedures for this vehicle