2021 Dodge RAM 1500 DT Service & Repair Manual
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09 - Engine, 5.7L / Standard Procedure
LONG BLOCK REPLACEMENT
Special Tools: Click to display a list of tools used in this procedure
REMOVAL
1. Remove the engine (Refer to 09 - Engine/Removal and Installation) .
2. Using a crisscross pattern, remove the bolts (1) and the flexplate.
3. Uncreate the NEW engine and mount on engine stand.
NOTE:
Do not use air tools to install Engine Lift Fixture (1) and Adapter (2).
4. Install the Fixture, Engine Lifting 8984C (1) and the Adapter, Engine Lift 8984-UPD (2) and securely tighten
the bolts.
5. Disconnect the left side and right side ignition coil wire harness connector (1).
6. Detach the three wire harness retainers from the left cylinder head cover.
7. Disconnect the left and right ignition capacitor wire harness connector (2).
8. Remove the two fasteners securing the wire harness to the back of the cylinder heads.
9. Remove the bolt (3) and the engine block heater (1).
10. Detach the four wire harness retainers from the right cylinder head cover.
11. Disconnect the Camshaft Position Sensor (CMP) sensor wire harness connector (1).
12. Disconnect the oil pressure sensor wire harness connector (1).
13. Disconnect the oil temperature sensor wire harness connector (1).
14. Remove the lower heater hose to oil cooler.
15. Remove the lower radiator hose from the water pump.
16. Remove the fastener securing the coolant hose from oil cooler to timing cover.
17. Remove the coolant hose from the timing cover.
18. Remove the coolant hose from the oil cooler.
Left side shown, right side similar
19. Disconnect the Crankshaft Position (CKP) wire harness connector (1).
20. Disconnect the right knock sensor wire harness connector (2).
21. Detach the two CMP wire harness retainers from the engine block.
22. Detach the two wire harness retainers from the right cylinder head.
23. Remove the engine wire harness from the engine.
24. Remove the bolts and the left engine mount.
25. Remove the bolts and the right engine mount.
26. Remove the water pump stretchy belt.
27. Remove the oil dipstick tube.
NOTE:
Do not pry on oil pan or oil pan gasket. The gasket is integral to engine windage tray
and does not come out with oil pan.
28. Remove the bolts (1) and the oil pan.
29. Clean the oil pan sealing surface.
30. Remove the nut (1), bolt (2) and the oil pump pickup tube.
31. Remove the appropriate belt tensioner(s) (Refer to 09 - Engine/Accessory Drive/TENSIONER, Belt/Removal and Installation) .
32. Remove the vibration damper bolt (1).
33. Using Crankshaft Insert 8513B and a commercially available puller, remove the vibration damper.
34. Using Seal Remover 9071 (1), remove the crankshaft front oil seal (2).
35. Clean the area around the front crankshaft oil seal.
36. Remove the five remaining bolts (1) and the timing cover.
37. Verify that timing cover slide bushing (1) is located in timing cover.
38. Clean the gasket sealing surface.
39. Remove the bolts and all four ignition coils (left side).
40. Using the sequence shown, remove the left cylinder head cover retaining bolts.
Right side shown, left side similar.
41. Remove the left cylinder head cover (1).
CAUTION:
Do not use harsh cleaners to clean the cylinder head covers. Severe damage to
covers may occur.
NOTE:
The cylinder head cover gasket may be used again, provided no cuts, tears, or
deformation have occurred.
42. Clean the sealing surface of the cylinder head (2).
43. Remove the three nuts and the left exhaust manifold head shield.
NOTE:
All fasteners removed must be installed in the same location they were removed from.
44. Using the sequence shown, remove the bolts and the left exhaust manifold.
45. Clean the gasket sealing surface.
46. Remove the bolts and all four ignition coils (right side).
47. Using the sequence shown, remove the right cylinder head cover retaining bolts.
Left side shown, right side similar
48. Remove the cylinder head cover (1).
CAUTION:
Do not use harsh cleaners to clean the cylinder head covers. Severe damage to
covers may occur.
NOTE:
The cylinder head cover gasket may be used again, provided no cuts, tears, or
deformation have occurred.
49. Clean the sealing surface of the cylinder head (2) and cover.
50. Remove the nuts (1) and the right exhaust manifold head shield.
NOTE:
All fasteners removed must be installed in the same location they were removed from.
51. Using the sequence shown, remove the bolts and the right exhaust manifold.
52. Clean the gasket sealing surface.
53. Remove the bolt (1) and the left knock sensor.
54. Remove the bolt (1) and the right knock sensor.
Left side shown, right side similar
55. Remove the bolt (2) and the CKP sensor.
56. Remove the nuts (1) and both ignition capacitors from the old engine.
57. Install both ignition capacitors on the NEW engine and tighten the nut (1) to the proper (Torque
Specifications) .
CAUTION:
Before tightening the CKP sensor mounting bolt, be sure the sensor is completely
flush to the cylinder block. If the CKP sensor is not flush, damage to the sensor
mounting tang may result.
58. Install the Crankshaft Position (CKP) sensor and tighten the bolt (2) to the proper (Torque Specifications) .
NOTE:
Over or under tightening the sensor mounting bolts will affect knock sensors
performance, possibly causing improper spark control. Always use the specified torque
when installing the knock sensors.
NOTE:
Do not apply any adhesive, sealant or thread locking compound to these bolts.
59. Install the right knock sensor and tighten the bolt (1) to the proper (Torque Specifications) .
60. Install the left knock sensor and tighten the bolt (1) to the proper (Torque Specifications) .
61. Clean the right exhaust manifold gasket sealing surface on the cylinder head.
NOTE:
All fasteners removed must be installed in the same location they were removed from.
62. Using a NEW gasket, install the right exhaust manifold and using the sequence shown, tighten the bolts to
25 N·m (18 ft. lbs.) allowing the gasket to seat to the exhaust manifold and cylinder head.
63. Re-check the torque at 25 N·m (18 ft. lbs.) using the sequence shown.
64. Install the right exhaust manifold heat shield and tighten nuts (1) to the proper (Torque Specifications) .
Right side shown, left similar.
CAUTION:
Do not use harsh cleaners to clean the cylinder head covers. Severe damage to
covers may occur.
NOTE:
The cylinder head cover gasket may be used again, provided no cuts, tears, or
deformation have occurred.
65. Clean the right cylinder head gasket sealing surface (2). Inspect and replace gasket if necessary.
66. Install the right cylinder head cover and using the sequence
shown, tighten the bolts to the proper (Torque Specifications)
.
67. Install all four right side ignition coils and tighten the bolts to the proper (Torque Specifications) .
68. Clean the left exhaust manifold gasket sealing surface on the cylinder head.
NOTE:
All fasteners removed must be installed in the same location they were removed from.
69. Using a NEW gasket, install the left exhaust manifold and using the sequence shown, tighten the bolts to 25
N·m (18 ft. lbs.) allowing the gasket to seat to the exhaust manifold and cylinder head.
70. Re-check the torque at 25 N·m (18 ft. lbs.) using the sequence shown.
Right side shown, left side similar.
71. Install the exhaust manifold heat shield and tighten nuts to the proper (Torque Specifications) .
CAUTION:
Do not use harsh cleaners to clean the cylinder head covers. Severe damage to
covers may occur.
NOTE:
The cylinder head cover gasket may be used again, provided no cuts, tears, or
deformation have occurred.
72. Clean the left cylinder head cover gasket sealing surface (2). Inspect and replace gasket if necessary.
73. Install the left cylinder head cover and using the sequence
shown, tighten the bolts to the proper (Torque Specifications)
.
NOTE:
Use dielectric grease on each of the spark plug boots before installing the coil.
74. Install all four left ignition coils and tighten the bolts to the proper (Torque Specifications) .
75. Clean the timing cover sealing surfaces
76. Install a NEW gasket (1) on the timing cover.
77. Verify that the slide bushing (1) is installed in timing cover.
78. Install the four timing cover bolts (1) and tighten to the proper (Torque Specifications) .
79. Install the timing cover slide bushing bolt (1) and tighten to the proper (Torque Specifications) .
CAUTION:
The front crankshaft seal must be installed dry. Do not apply lubricant to the sealing lip or the outer edge.
80. Using the Installer, Front Damper 2042300090 , install the NEW front crankshaft oil seal.
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2021 Dodge RAM 1500 DT Service & Repair Manual
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