Chrysler RAM TRUCK 2500 1994 Service Manual page 847

9 126 5.9L (DIESEL) ENGINE
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(25) Disconnect ail electrical connections from the
engine. Put tags on the connections to identify their
locations.
(26) Disconnect the fuel lines to the lift pump and
fuel return. Use tags to identify the lines.
(27) On Manual Transmission vehicles, remove the
shift lever (refer to Group 21, Transmissions).
(28) Raise and support the vehicle on a hoist.
(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.
(33) 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) AUTOMATIC TRANSMISSION:
(a) Support transmission. This will assure that
the torque converter will remain i n proper position
in the transmission housing.
(b) Remove torque converter bolts.
(c) Remove transmission bolts.
(37) M A N U A L TRANSMISSION!
(a) Remove the prop shaft (refer to Group 16,
Propeller Shaft).
(b) Support transmission.
(c) Remove rear transmission support.
(d) Remove the crossmember.
(e) Remove the clutch assembly and slave cylin­
der.
(f) Disconnect all wiring and connectors.
(g) Remove transmission bolts. Remove the
transmission.
(h) Remove the bell housing.
(i) Remove clutch assembly.
(j) Remove flywheel and ring gear.
(38) Lower the vehicle.
(39) Install a jack stand under the automatic
transmission.
(40) Put a cover or tape over all engine openings.
(41) Lift the engine out of the vehicle.
(42) Install the engine on a suitable stand.
(43) Remove all accessories and brackets not previ­
ously 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 en­
gine 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 i n the chassis with the
thru-bolt installed.
(5) Remove the covers or tape covering the engine
openings.
(6) Remove the jack stand from under the auto­
matic transmission.
(7) Raise and support the vehicle.
(8) AUTOMATIC TRANSMISSION;
(a) Install and tighten the transmission bolts.
(b) Install and tighten the torque converter bolts.
(c) Remove the support from the transmission.
(9) M A N U A L TRANSMISSIONS
(a) Install flywheel and ring gear.
(b) Install clutch assembly.
(c) Install the bell housing.
(d) Install the transmission and bolts.
(e) Connect all wiring and connectors.
(f) Install the clutch assembly and slave cylinder.
(g) Install the crossmember.
(h) Install rear transmission support.
(i) Remove the support from the transmission,
(j) Install the prop shaft (refer to Group 16, Pro­
peller Shaft).
(10) Install the dust shield and transmission cover.
(11) Install the starter motor (refer to Group 8B,
Battery/Starter/Generator Service). Connect the
starter wires.
(12) Install the transmission cooler line brackets to
oil pan.
(13) Install and tighten engine front mount thru-
bolt nuts.
(14) Install the oil pan. Install the drain plug.
(15) Lower the vehicle.
(16) On Manual Transmission vehicles, install the
shift lever (refer to Group 21, Transmissions).
(17) Connect the fuel lines to the lift pump and
fuel return. Use tags to identify the lines.
(18) Connect all electrical connections to the en­
gine. Use tags to identify their locations.
(19) Connect the transmission cooler lines.
(20) Connect the power steering hoses, i f equipped.
(21) Connect the accelerator linkage, the speed
control linkage and the throttle valve linkage.
(22) Install the outlet duct. Connect the intercooler
outlet duct to the air inlet housing and the inter­
cooler.
(23) Install the inlet duct. Connect the intercooler
inlet duct to the turbocharger and the intercooler.
(24) Install the exhaust pipe to the turbocharger
outlet flange.
(25) Install the air inlet tube. Connect the air inlet
tube to the turbocharger and the air intake housing.
(26) Connect the heater hoses at the dash panel
and at the water valve.
(27) Install the generator and wire connections (re­
fer to Group 8B, Battery/Starter/Generator Service).