Dodge ram truck 3500 1996 Service Manual page 1171

5,91 (DIESEL) ENGINE 9 - 181
REMOVAL AND INSTALLATION (Continued)
Fig. 44 Air inlet Tube and Exhaust Pipe Connection
(29) Drain the engine lubricating oil. Dispose of
the oil according to all applicable regulations.
(30) Remove the oil pan.
(31) Remove engine front mount thru-bolt nuts.
(32) Remove the transmission cooler line brackets
from oil pan.
(38) Disconnect exhaust pipe at manifold.
(34) Disconnect the starter wires. Remove starter
motor (refer to Group 8B, Battery/Starter/Generator
Service).
(35) Remove the dust shield and transmission
cover.
(36) Refer to Group 21, Transmissions for trans­
mission removal.
(37) Lower the vehicle.
(38) Put a cover or tape over all engine openings.
(39) Lift the engine out of the vehicle.
(40) Install the engine on a suitable stand.
(41) Remove all accessories and brackets not pre­
viously removed for use with the replacement engine.
INSTALLATION
(1) Check the data,plate to verify that the replace­
ment . engine is the same model and rating as the
engine that was removed.
(2) Install all accessories and brackets that had
been removed from the previous engine.
(3) Use the lifting brackets to lift the engine off of
the stand.
(4) Position the engine in the chassis with the
thru-bolt installed.
(5) Remove the covers or tape covering the engine
openings.
(6) Raise and support the vehicle.
(7) Refer to Group 21, Transmissions for transmis­
sion installation.
(8) Install the dust shield and transmission cover.
(9) Install the prop shaft (refer to Group 16, Pro­
peller Shaft).
(10) Install the starter motor (refer to Group 8B,
Battery/Starter/Generator Service). Connect the starter
wires.
(11) Install the transmission cooler line brackets to
oil pan.
(12) Install and tighten engine front mount thru-
bolt nuts.
(13) Install the oil pan. Install the drain plug.
(14) Lower the vehicle.
(15) On Manual Transmission vehicles, install the
shift lever (refer to Group 21, Transmissions).
(16) Connect the fuel lines to the lift pump and
fuel return. Use tags to identify the lines.
(17) Connect all electrical connections to the
engine. Use tags to identify their locations.
(18) Connect the transmission cooler lines.
(19) Connect the power steering hoses, i f equipped.
(20) Connect the accelerator linkage, the speed
control linkage and the throttle valve linkage.
(21) Install the outlet duct. Connect the intercooler
outlet duct to the air inlet housing and the intercooler.
(22) Install the inlet duct. Connect the intercooler
inlet duct to the turbocharger and the intercooler.
(23) Install the exhaust pipe to the turbocharger
outlet flange.
(24) Install the air inlet tube. Connect the air inlet
tube to the turbocharger and the air intake housing.
(25) Connect the heater hoses at the dash panel
and at the water valve.
(26) Install the generator and wire connections
(refer to Group 8B, Battery/Starter/Generator Ser­
vice).
(27) Install the radiator (refer to Group 7, Cooling
System).
(28) Connect the lower radiator hose.
(29) Install the fan shroud.
(30) Install the fan.
(31) Connect the top radiator hose.
(32) Install the radiator overflow bottle.
(33) Install the washer bottle.
(34) I f equipped, install the condenser.
(35) Install the A/C compressor with the lines
attached.
(36) Evacuate and charge the air conditioning sys­
tem, i f equipped (refer to Group 24, Heating and Air
Conditioning for service procedures).
(37) Install the transmission oil cooler.
(38) Install the upper crossmember and top core
support.
(39) Install the serpentine belt (refer to Group 7,
Cooling System).