Dodge Ram Truck 1500-2500-3500. Manual — part 1409

The Filter Minder™ (5) consists of a diaphragm and
calibrated spring sealed inside of a plastic housing. A
yellow colored disc (2) attached to diaphragm moves
along a graduated scale on side of Filter Minder. After
the engine has been shut off, a ratcheting device
located within Filter Minder will hold yellow disc at
highest restriction that air cleaner element has experi-
enced. A drop in air pressure due to an air cleaner
element restriction moves diaphragm and yellow disc
will indicate size of air drop.

CAUTION: Certain engine degreasers or cleaners
may discolor or damage plastic housing of Filter
Minder. Cover and tape Filter Minder if any engine
degreasers or cleaners are to be used.

To test, turn engine off. If yellow disc (2) has reached
red colored zone (3) on graduated scale, air cleaner
element should be replaced. Refer to Removal /
Installation.

Resetting Filter Minder: After air cleaner (filter) ele-
ment has been replaced, press rubber button on top of Filter Minder. This will allow yellow colored disc to reset.
After button has been pressed, yellow disc should spring back to UP position.

If Filter Minder gauge has reached red colored zone, and after an examination of air cleaner (filter) element, ele-
ment appears to be clean, high reading may be due to a temporary condition such as snow build-up at air intake.
Temporary high restrictions may also occur if air cleaner (filter) element has gotten wet such as during a heavy rain
or snow. If this occurs, allow element to dry out during normal engine operation. Reset rubber button on top of Filter
Minder and retest after element has dried.

Filter Removal

1. The housing cover is equipped with spring clips

and is hinged with plastic tabs. Unlatch clips from
top of air cleaner housing and tilt housing cover up
for cover removal.

2. Remove air cleaner element from air cleaner hous-

ing (5).

INSTALLATION

1. Before installing new air cleaner element (filter), clean inside of air cleaner housing.

2. Position air cleaner cover to tabs on front of air cleaner housing. Latch spring clips to seal cover to housing.

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CYLINDER HEAD

DESCRIPTION

The cylinder head is constructed of cast iron and is a one piece cross flow design with four valves per cylinder. The
arrangement of two intake and two exhaust valves per cylinder allows for a centrally located injector. The cylinder
head also includes an integral intake manifold, an integral thermostat housing, and a longitudal fuel return rifle,
which exits at the rear of the head. The 24 valve design also includes integrally cast valve guides and hardened
intake and exhaust valve seat inserts.

REMOVAL

1. Disconnect battery negative cables.

2. Raise vehicle on hoist.

3. Drain engine coolant.

4. Disconnect exhaust pipe from turbocharger elbow.

5. Remove turbocharger drain tube bolts at turbocharger. Cap off ports to prevent dirt or foreign material from enter-

ing.

6. Lower vehicle.

7. Disconnect air inlet temperature/pressure sensor.

8. Remove air cleaner housing and snorkel from the vehicle. Cap off turbocharger air inlet to prevent intrusion of

dirt or foreign material.

9. Disconnect cab heater core supply and return hoses from the cylinder head and heater pipe.

10. Disconnect turbocharger oil supply line at the turbocharger end. Cap off open ports to prevent intrusion of dirt

or foreign material.

11. Remove exhaust manifold-to-cylinder head bolts, spacers, heat shield, retention straps, and cab heater plumb-

ing. Remove exhaust manifold and turbocharger from the vehicle as an assembly.

12. Remove cooling fan/drive/shroud assembly. (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL)

13. Remove accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).

14. Remove cooling fan support from cylinder block.

15. Remove upper generator bolt, loosen lower generator bolt, and rotate generator away from cylinder head.

16. Disconnect radiator upper hose from the thermostat housing.

17. Disconnect the Intake Air Temperature/Manifold Air Pressure, and Coolant Temperature sensor connectors.

18. Remove the engine harness to cylinder head attaching bolts and P-clips at front of head.

19. Remove the throttle linkage cover.

20. Remove the intake air grid heater wires from the grid heater.

21. Remove engine oil level indicator tube attaching bolt at fuel filter housing bracket and inlet air connection..

22. Remove the charge air cooler-to-air inlet housing pipe.

23. Remove the engine wire harness attaching bolt and wire harness push-in fastener from air inlet housing.

24. Remove the air inlet housing and intake grid heater from the intake manifold cover.

25. Remove the two grid heater harness-to-cylinder head attaching bolts at front of cylinder head.

26. Remove the high pressure pump to fuel rail fuel line as follows:

a. Loosen fuel line nuts at fuel pump and at fuel rail.

b. Use a back-up wrench on the fitting at the fuel pump to keep it from loosening.

27. Remove the fuel rail to cylinder head fuel lines as follows:

a. Loosen No. 6 high pressure fuel line shield and position out of way.

b. Loosen the fuel line nuts at the fuel rail and at the cylinder head. Use a back-up wrench on HPC nut.

c. Remove the fuel line bracket bolts at the intake manifold cover.

28. Remove the engine lift bracket from the rear of the cylinder head.

29. Remove the fuel rail as follows:

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a. Remove fuel rail pressure sensor connector.

b. Remove banjo fitting at pressure limiting valve.

c. Remove fuel rail bolts and fuel rail.

30. Remove the low pressure lines as follows:

a. Remove the fuel drain banjo fitting on the front side of fuel filter housing.

b. Remove the fuel drain banjo fitting on rear side of fuel filter housing.

c. Remove the fuel drain line support bracket on rear side of filter housing.

d. Disconnect fuel drain hose.

e. Remove banjo fitting at bottom of fuel filter housing.

f. Disconnect fuel supply hose at fuel filter.

31. Disconnect fuel heater, and water in fuel sensor.

32. Remove the fuel filter assembly-to-cylinder head bolts and remove filter assembly from vehicle.

33. Remove wire harness P-clip from cylinder head (located behind filter housing).

NOTE: Verify that the cylinder head cover ground spring is retained in the cylinder head cover.

34. Remove the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) -

REMOVAL).

35. Disconnect rocker housing injector harness connectors.

36. Remove injector harness nuts from injectors.

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37. Remove the rocker levers (1), cross heads and

push rods. Mark each component so they can be
installed in their original positions.

NOTE: The #5 cylinder exhaust and the #6 cylinder
intake and exhaust push rods are removed by lift-
ing them up and through the provided cowl panel
access holes. Remove the rubber plugs to expose
these relief holes.

38. Remove the fuel return line and banjo bolt at the rear of the cylinder head. Be careful not to drop the two (2)

sealing washers.

39. Remove the fuel injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - REMOVAL).

40. Remove rocker housing bolts and rocker housing and gasket.

41. Reinstall the engine lift bracket at the rear of cylinder head. Torque to 77 N·m (57 ft. lbs.).

42. Remove twenty six (26) cylinder head-to-block bolts.

43. Attach an engine lift crane to engine lift brackets and lift cylinder head off engine and out of vehicle.

44. Remove the head gasket and inspect for failure.

CLEANING

CLEANING—CYLINDER HEAD

CAUTION: Do not wire brush head surface while fuel injectors are still installed. Fuel injector damage can
result.

Remove fuel injectors before cleaning (if not already removed during cylinder head removal).

Clean the carbon from the injector nozzle seat with a nylon or brass brush.

Scrape the gasket residue from all gasket surfaces.

Wash the cylinder head in hot soapy water solution (88°C or 140°F).

After rinsing, use compressed air to dry the cylinder head.

Polish the gasket surface with 400 grit paper. Use an orbital sander or sanding block to maintain a flat surface.

CLEANING—CROSSHEADS

Clean all crossheads in a suitable solvent. If necessary, use a wire brush or wheel to remove stubborn deposits.
Rinse in hot water and blow dry with compressed air.

CLEANING—PUSHRODS

Clean the pushrods in a suitable solvent. Rinse in hot water and blow dry with compressed air. If necessary, use a
wire brush or wheel to remove stubborn deposits.

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