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6.7L Diesel Engine - Service Information: Specifications RAM Pickup 3500

Mechanical 15 illustrations ~1678 words

TORQUE SPECIFICATIONS

DESCRIPTIONN.mIn. Lbs.Ft. Lbs.
Connecting Rod - Bolts
Step 13022
Step 26044
Step 3Rotate 60 degrees
CAUTION: The 6.7L engine has different torque procedures for new and previously installed main bearing capscrews. Failure to use the correct torque procedure can result in engine damage.
Crankshaft Main Cap - Bolts (Previously Used)
Step 16044
Step 28059
Step 3Rotate 90°
Crankshaft Main Cap - Bolts (New Main Bearing Capscrews)N.mIn. Lbs.Ft. Lbs.
Step 112089
Step 2Loosen completelyLoosen completely
Step 36044
Step 48563
Step 5Rotate 120°
Cylinder Head - Bolts
Step 17052
Step 2Back off 360 degrees
Step 310577
Step 4 Verify10577
Step 5Rotate All Bolts 1/4 Turn
Cylinder Head Cover Bolts2418
Accessory Drive Belt Tensioner Bolt4332
Air Inlet to Intake Manifold Bolts2418
Air Cleaner Body Bolt870
Air Cleaner Intake Air Tube Clamp435
Bell Housing Access Cover Bolts1089
Block Stiffener Bolts4332
Breather Cover Bolts1089
Charge Air Cooler Bolt218
Charge Air Tube Clamps1197
Coolant Outlet Tube Bracket Bolt1089
Coolant Outlet Tube Bracket Nut2418
Crankshaft Damper Bolts40 + 60°30 + 60°
Delta-P line Bracket Bolt1089
Delta-P line Bracket Nut2418
Delta-P Flare Nut1089
Dual Mass Flywheel Bolts5440
Engine Cover Bolts1089
Engine Mount Bolt9570
Engine Mount Through Bolt Nut12995
Engine Wire Harness P-clip Bolts2418
Exhaust Manifold Bolts4337
Exhaust Manifold Heat Shield Nuts2418
Fan Support Hub3224
Flexplate to Engine137100
Flywheel to Engine137100
Flywheel/Crankshaft Adapter137100
Flywheel Housing Bolts7757
Forward Coolant Tube Bracket Bolts1089
Forward Coolant Tube Bolts1089
Front Cover2418
Fuel Delivery Lines - Banjo2418
Fuel Drain Line - Banjo2418
Fuel Injector Harness Nuts1.2511
Fuel Injector Hold-down544
Step 21089
Fuel Injector Solenoid Nuts1.2511
Fuel Tube, No. 6 Bracket Shield Bolts4332
Fuel Tube - Rail to Cylinder Head4030
Fuel Tube - Pump to Fuel Rail3727
Fuel Rail Hold-down Bolt2418
Gear Housing Cover2418
HPC Nut5037
Intake Manifold Bolts2418
Intake Manifold Grid Heater Wire Harness Bolts1089
Oil Cooler Bolts2418
Oil Dip Stick Tube Bolt2418
Oil Dip Stick Tube Nut980
Oil Pan - Bolts2821
Oil Pan - Drain Plug5037
Oil Pressure Regulator - Plug8059
Oil Pressure Switch to Block Fitting1813
Oil Pressure Switch to Block Fitting to Block3022
Oil Pump - BoltsRefer to PUMP, Engine Oil , Installation , 6.7L .
Oil Suction Tube (Flange) - Bolts2418
Oil Suction Tube (Brace) - Bolt4332
Oxygen Sensor4130
P-Clip Bolt2418
Rack and Pinion Steering Gear to Frame Bolts (4X2)251185
Rocker Arm Housing Bolts2418
Rocker Arm/Pedestal - Bolts3627
Rocker Housing Bolts2418
Starter Motor Bolts4030
Torque Converter Bolts8865
Transmission to Engine Bolts (automatic)4130
Transmission to Engine Bolts (manual)4533
Transmission Mount to Crossmember Nuts4735
G 56 Transmission Mount Bolts5037
68RFE Transmission Mount Bolts5037
AS68RC Transmission Mount Nuts4735
AS68RC Transmission Mount Support Bracket Bolts5440
AS68RC Transmission Side Support Bracket Bolt5541
AS68RC Transmission Upper Bracket Nut3022
Turbocharger Actuator Bolt1197
Turbocharger Air Inlet Tube Clamp1197
Turbocharger Cleaning Port Plug1089
Turbocharger Coolant Return Line Banjo Bolt2418
Turbocharger Coolant Supply Line Banjo Bolt2418
Turbocharger Nuts4332
Turbocharger Oil Drain Tube Bolt3627
Turbocharger Oil Supply Line Nut3627
Turbocharger Speed Sensor Bolt1089
Turbocharger V-Band Clamp Nut1089
Valve Lash Adjusting Nut2418
CAUTION
The 6.7L engine has different torque procedures for new and previously installed main bearing capscrews. Failure to use the correct torque procedure can result in engine damage.

6.7L DIESEL ENGINE

Scheme 475

Scheme 475: REMOVAL
Scheme 475: REMOVAL

Scheme 476

Scheme 476
Scheme 476

Scheme 477

Scheme 477
Scheme 477

Scheme 478

Scheme 478
Scheme 478

Scheme 479

Scheme 479
Scheme 479

Scheme 480

Scheme 480
Scheme 480

Scheme 481

Scheme 481
Scheme 481

Scheme 482

Scheme 482
Scheme 482

Scheme 483

Scheme 483
Scheme 483

Scheme 484

Scheme 484
Scheme 484

Scheme 485

Scheme 485
Scheme 485

Scheme 486

Scheme 486
Scheme 486
  1. Remove bolts (1) and the engine cover (2).
  2. Disconnect the hood support struts and position hood out of the way.
  3. Disconnect both negative and positive battery cables.
  4. Drain cooling system. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
  5. Remove the air cleaner body. Refer to «BODY, Air Cleaner , Removal , 6.7L»(ref-457798-S28601491212012030200000) .
  6. Recover A/C refrigerant. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
  7. Drain engine oil.
  8. Reinstall drain plug. Tighten to 50 N.m (37 ft. lbs.).
  9. Remove bolts (1) and the bell housing access cover (2).
  10. Install the Barring Tool (special tool #7471B, Barring Tool) (1).
  11. Using the Barring Tool (special tool #7471B, Barring Tool) (1), rotate the engine and remove the torque converter bolts. On manual transmission models, remove the dual mass flywheel bolts.
  12. Remove the Barring Tool (special tool #7471B, Barring Tool) (1).
  13. Remove the left ground strap.
  14. Disconnect the transmission harness connector.
  15. Remove the radiator closure panel. Refer to «PANEL, Closure, Radiator , Removal»(ref-457777-S11960417672012030200000) .
  16. Remove the fan and fan shroud. Refer to «FAN, Cooling, Electric , Removal»(ref-457792-S13033663812012030200000) .
  17. Disconnect the upper and lower radiator hoses and remove the radiator.
  18. Remove the serpentine drive belt. Refer to «BELT, Serpentine , Removal»(ref-457792-S18686393612012030200000) .
  19. Remove the power steering reservoir. Refer to «RESERVOIR, Power Steering Pump , Removal»(ref-457772-S40498460022012030200000) .
  20. Remove the power steering pump. Refer to «Pump , Removal»(ref-457772-S19330296352012030200000) . NOTE: Illustration shown with lower radiator hose removed for clarity.
  21. Remove the nuts (1) that secure the A/C suction line (3) and the A/C discharge line (4) to the A/C compressor (2).
  22. Disconnect the A/C suction and discharge lines from the A/C compressor and remove and discard the O-ring seals and gaskets.
  23. Install plugs in, or tape over the opened refrigerant line fittings and compressor ports.
  24. Disconnect engine wiring harness connector from Totally Integrated Power Module (TIPM).
  25. Remove the starter cable at the left battery and power distribution center.
  26. Disconnect the intake heater connector.
  27. Remove the battery negative cables to the engine block on the driver and passenger side.
  28. Disconnect the generator harness wires.
  29. Disconnect the block heater harness connector.
  30. Disconnect the left side, engine block to frame, ground wire. NOTE: Do not remove the elbow (1) from the turbocharger.
  31. Remove the V-clamp (2) from the exhaust pipe-to-turbocharger outlet elbow connection.
  32. Disconnect the heater core supply and return hoses.
  33. Disconnect the fuel supply and return lines from the fuel filter housing. NOTE: Starter, transmission, and flex plate/flywheel removed for clarity.
  34. Remove the transmission collar (1).
  35. Remove the engine to transmission bolts.
  36. Remove the cylinder head cover (1). Refer to «COVER(S), Cylinder Head , Removal , 6.7L»(ref-457798-S18243865832012030200000) .
  37. Disconnect the injector wiring harness connectors to injector connections on cylinder head cover carrier gasket (3).
  38. Remove the injector harness nuts to injectors (1).
  39. Remove the cylinder head cover/injector wiring gasket (2).
  40. Remove the EGR cooler. Refer to «COOLER, EGR , Removal»(ref-457792-S12900673252012030200000) . NOTE: Mark the location of pushrods and crossheads for reinstallation.
  41. Remove the rocker arms (1), pedestals (2), and pushrods for cylinders No. 4, No 5, and No. 6. 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.
  42. Remove the No. 6 high pressure fuel line shield.
  43. Remove the No. 5 and No. 6 high pressure fuel line.
  44. Remove the HPC connector tube and nut.
  45. Remove the No. 5 and No. 6 fuel injector.
  46. Remove the No. 4 and No. 5 head bolts.
  47. Install the front and rear engine lift bracket. Tighten to 77 N.m (57 ft. lbs).
  48. Remove the two cylinder head bolts (1 and 3) according to the diagram and install the Engine Lifting Bracket (special tool #9009, Bracket, Engine Lifting) (2). Tighten bolts to 105 N.m (77 ft. lbs.).
  49. Attach a chain with two hooks to the engine lift brackets.
  50. Remove the engine mount through bolts and nuts.
  51. While keeping engine level, lift straight up out of the mounts.
  52. Rotate the nose of engine upward and pull out of chassis.

Scheme 487

Scheme 487: INSTALLATION
Scheme 487: INSTALLATION

Note. A new clamping ring must be used any time the flex plate or flywheel adapter is removed.

Scheme 488

Scheme 488
Scheme 488

Scheme 489

Scheme 489
Scheme 489
  1. If removed, install the flywheel and adapter or flexplate. Tighten bolts to 137 N.m (100 ft. lbs). 1 - Head bolt 2 - Engine Lift Bracket 3 - Head Bolt
  2. Remove the cylinder head bolts (1 and 3) according to the diagram. Install special Tool (special tool #9009, Bracket, Engine Lifting) (2). Tighten bolts to 105 N.m (77 ft. lbs.).
  3. Lower the engine into the engine compartment and install the engine mount through bolts and nuts.
  4. Tighten the mount through bolts and nuts to 129 N.m (95 ft. lbs).
  5. Remove the chain with 2 hooks and the Engine Lifting Bracket (special tool #9009, Bracket, Engine Lifting) (2).
  6. Check the cylinder head bolt length and install into cylinder head.
  7. Torque in 4 steps to: Step 1 - Tighten to 70 N.m (52 ft. lbs.). Step 2 - Back off 360°. Step 3 - Tighten to 105 N.m (77 ft. lbs.). Step 4 - Rotate 90°.
  8. Replace injector O-ring and sealing washer on injectors No. 5, No. 6. Install injectors and tighten using the following steps: Step 1 - Install the injector hold-down capscrews and tighten to 5 N.m (44 in. lbs.). Step 2 - Loosen the injector hold-down capscrews. Step 3 - Install the HPC connector tube and nut. Tighten nut to 15 N.m (133 in. lbs.). Step 4 - Tighten the injector hold-down capscrews to 10 N.m (89 in. lbs.). Step 5 - Tighten the HPC connector tube nut to 50 N.m (37 ft. lbs.).
  9. Remove the front and rear engine lift bracket.
  10. If fuel tube at No. 6 cylinder has been removed, tilt metal bracket (4) upward to install the No. 6 fuel tube finger tight.
  11. Install the No. 5 and No. 6 high pressure fuel lines. Tighten fuel line fittings to 40 N.m (35 ft. lbs.).
  12. Position the metal bracket (4) at the rear of cylinder head back and tighten bolts (3) to 43 N.m (32 ft. lbs.).
  13. Install the pushrods, rocker arms (1), and pedestals (2) for cylinders No. 4, No. 5, and No. 6. Tighten the mounting bolts to 36 N.m (27 ft. lbs).
  14. Reset the valve lash on cylinders No. 4, No. 5, and No. 6. for the intake valve at 0.254 mm (0.010 in.) and exhaust valve at 0.66 mm (0.026 in.). Tighten adjusting nuts to 24 N.m (18 ft. lbs.).
  15. Install the EGR cooler. Refer to «COOLER, EGR , Installation»(ref-457792-S13222462612012030200000) .
  16. Install the cylinder head cover/injector wiring gasket (2).
  17. Install the injector harness nuts to injectors (1). Tighten to 1.25 N.m (11 in. lbs.).
  18. Connect the injector wiring harness connectors to injector connections on cylinder head cover carrier gasket (3).
  19. Install the cylinder head cover (1). Refer to «COVER(S), Cylinder Head , Installation , 6.7L»(ref-457798-S32938384582012030200000) .
  20. Install the transmission to engine bolts. Automatic transmission, tighten bolts to 41 N.m (30 ft. lbs.). Manual transmission, tighten bolts to 45 N.m (33 ft. lbs.).
  21. Install the transmission collar (1). Tighten to 77 N.m (57 ft. lbs.).
  22. Connect the fuel supply and return lines from the fuel filter housing.
  23. Connect the heater core supply and return hoses.
  24. Using a new V-clamp, install the exhaust pipe to the turbocharger elbow (1). Tighten V-clamp to 11 N.m (97 in. lbs.).
  25. Connect left side, engine block to frame ground wire.
  26. Connect the engine block heater harness connector.
  27. Connect the generator harness wires.
  28. Install the battery negative cables to the engine block on the driver and passenger side.
  29. Connect the intake heater connector.
  30. Install the starter cable to the left battery and power distribution center.
  31. Connect engine wiring harness connector from Totally Integrated Power Module (TIPM). NOTE: Illustration shown with lower radiator hose removed for clarity.
  32. Remove the tape or plugs from the opened refrigerant line fittings and compressor ports.
  33. Lubricate new O-ring seals with clean refrigerant oil and install them and a new gasket onto the refrigerant line fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  34. Connect the A/C suction line (3) and A/C discharge line (4) to the A/C compressor (2).
  35. Install the A/C suction and discharge line assembly to the compressor. Tighten the nuts to 23 N.m (17 ft. lbs.).
  36. Install the power steering pump. Refer to «Pump , Installation»(ref-457772-S27109949282012030200000) .
  37. Install the power steering reservoir. Refer to «RESERVOIR, Power Steering Pump , Installation»(ref-457772-S40176430132012030200000) .
  38. Install the serpentine drive belt. Refer to «BELT, Serpentine , Installation»(ref-457792-S21966014282012030200000) .
  39. Install the fan and fan shroud. Refer to «FAN, Cooling, Electric , Installation»(ref-457792-S30022413072012030200000) .
  40. Install the radiator and connect the upper and lower radiator hoses.
  41. Install the radiator closure panel. Refer to «PANEL, Closure, Radiator , Installation»(ref-457777-S33505263742012030200000) .
  42. Connect the transmission harness connector.
  43. Install the left ground strap.
  44. Install the Barring Tool (special tool #7471B, Barring Tool) (1).
  45. Using the Barring Tool (special tool #7471B, Barring Tool) (1), rotate the engine and install the torque converter bolts. Tighten bolts to 88 N.m (65 ft. lbs.). On manual transmission models, install the dual mass flywheel bolts. Tighten bolts to 88 N.m (65 ft. lbs.).
  46. Remove the Barring Tool (special tool #7471B, Barring Tool) (1).
  47. Install the bell housing access plate. Tighten bolts to 10 N.m (89 in. lbs.).
  48. Change the oil filter and fill with recommended new engine oil.
  49. Evacuate and recharge A/C system. Refer to «Plumbing , Standard Procedure»(ref-457787-S01365783702012030200000) .
  50. Fill the cooling system with coolant. Refer to «Standard Procedure»(ref-457792-S30781673372012030200000) .
  51. Install the air cleaner body. Refer to «BODY, Air Cleaner , Installation , 6.7L»(ref-457798-S12411770922012030200000) .
  52. Connect both negative and positive battery cables.
  53. Start the engine and inspect for engine oil, coolant, and fuel leaks.
  54. Position the hood and connect hood support struts.
  55. Install the engine cover. Tighten bolts (1) to 10 N.m (89 in. lbs.).

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