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6.4L Engine (Service Information): Installation

CAUTION:

If the engine encounters a catastrophic failure, the engine oil cooler and lines must be replaced or damage to the new engine or components could result.

NOTE:

The coolant hoses to the block mounted engine oil coolers do not require replacement, only the oil lines on vehicles equipped with a remote engine oil cooler.

CAUTION:

If the original engine has experienced a catastrophic failure or an individual failure with the piston, cylinder bore, engine block, valve or valve seat, the intake manifold MUST be replaced with a new manifold.

GC0080289Courtesy of CHRYSLER GROUP, LLC
NOTE:

Do not use air tools to install the engine lifting fixture (2).

(special tool #8984C, Fixture, Engine Lifting)

  1. Install the engine lifting fixture (2) and adapter (4).

    (special tool #8984C, Fixture, Engine Lifting) and (special tool #8984-UPD, Adapter, Engine Lift)

  2. Using a suitable engine hoist, lower the engine into the engine compartment.
  3. Automatic transmission equipped vehicles, align the engine with the transmission.
  4. Install two transmission bell housing to engine block bolts finger tight.
  5. Lower the engine assembly until the engine mounts rest in the engine cradle crossmember.
    GC0144614Courtesy of CHRYSLER GROUP, LLC
  6. Align the engine mounts, install both left/right engine mount to frame retaining bolts (2) and tighten to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  7. Position both left and right engine mount heat shields (4), install the retaining nuts (3) and tighten to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  8. Remove the engine hoist and the jack supporting the transmission.
  9. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
  10. For manual transmission equipped vehicles, install the transmission. Then proceed to step 19.
  11. For automatic transmission equipped vehicles, follow steps 12-18.
  12. Carefully engage transmission to engine block dowels until converter hub is seated in crankshaft. Verify that no wires, or the transmission vent hose, have become trapped between the engine block and the transmission.
  13. Install two bolts to attach the transmission to the engine.
    GC0118998Courtesy of CHRYSLER GROUP, LLC
  14. Install remaining torque converter housing to engine bolts (3 and 4). Tighten all torque converter housing bolts to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0158383Courtesy of CHRYSLER GROUP, LLC
  15. Install all torque converter bolts (1) by hand first. There are three sets of two bolts 120° apart.
  16. Tighten all torque converter bolts to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0158334Courtesy of CHRYSLER GROUP, LLC
  17. Install the engine structural cover and tighten the bolts (1) to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    NOTE:

    The left front structural cover bolt (2) must be installed with the cover.

  18. Install the starter. Refer to STARTER, INSTALLATION .
    GC0095565Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The Crankshaft Position (CKP) sensor is located at the right rear side of the engine block.

  19. Connect the CKP sensor wire harness connector (1).
    GC0170123Courtesy of CHRYSLER GROUP, LLC
  20. Position the catalytic converters (1) onto the exhaust manifold flanges, install the flange nuts (2) and tighten to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0170237Courtesy of CHRYSLER GROUP, LLC
  21. Connect the oxygen sensor (1) wire harness connectors (2).
    GC0144624Courtesy of CHRYSLER GROUP, LLC
  22. Connect the right and left knock sensor (1) wire harness connectors (3).
  23. Install the heat shields onto both knock sensors (shield snaps on/off sensor).
  24. Connect the transmission oil cooler lines to their retainers at the oil pan.
    GC0095212Courtesy of CHRYSLER GROUP, LLC
  25. Install the lower radiator hose (1).
  26. Lower the vehicle.
    GC0080289Courtesy of CHRYSLER GROUP, LLC
  27. Remove the engine lifting fixture (2) and adapter (4).

    (special tool #8984C, Fixture, Engine Lifting) and (special tool #8984-UPD, Adapter, Engine Lift)

  28. Position the left and right side wiring harness.
    GC0144407Courtesy of CHRYSLER GROUP, LLC
  29. Lubricate the Oil Control Valve (OCV) rubber O-ring seal with clean engine oil.
  30. Install the OCV (3) and rotate into position.
  31. Install the OCV retaining bolt (2) and tighten to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  32. Connect the OCV wire harness connector (1).
    GC0144611Courtesy of CHRYSLER GROUP, LLC
  33. Position the heater tube (3) into the water pump.
  34. Install the heater tube retaining bolt (1) and tighten to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  35. Connect the wire harness connector to the coolant temperature (ECT) sensor (2).
    GC0148461Courtesy of CHRYSLER GROUP, LLC
  36. Connect the camshaft position sensor wire harness connector (1).
  37. Install the intake manifold. Refer to MANIFOLD, INTAKE, INSTALLATION .
    GC0095566Courtesy of CHRYSLER GROUP, LLC
  38. Connect the heater hoses (1, 2).
  39. Connect the ground wires to the rear of each cylinder head.
    GC0080072Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The ignition capacitor (2) is attached to the rear of the left cylinder head.

  40. Connect the ignition capacitor (2) wire harness connector (1).
    GC0170349Courtesy of CHRYSLER GROUP, LLC
  41. Connect the oil pressure sensor wire harness connector (1).
    GC0170570Courtesy of CHRYSLER GROUP, LLC
  42. Connect the oil temperature sensor wire harness connector (1).
  43. Install the generator. Refer to GENERATOR, INSTALLATION .
  44. Raise and support the vehicle.
    GC0144621Courtesy of CHRYSLER GROUP, LLC
  45. Position the generator support bracket (3) to the engine mount, install the retaining nut (1) finger tight.
  46. Position the generator support bracket to the generator, install the retaining bolt (2) and tighten to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  47. Tighten the generator support bracket to engine mount retaining nut (1) to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  48. Install the A/C compressor. Refer to COMPRESSOR, A/C, REMOVAL .
    GC0095584Courtesy of CHRYSLER GROUP, LLC
  49. Install the belly pan and securely tighten the fasteners (1).
  50. Remove support and lower the vehicle.
    GC0080075Courtesy of CHRYSLER GROUP, LLC
  51. Position the ignition coil wire harness and connect all ignition coil wire harness connectors (1).
    GC0144485Courtesy of CHRYSLER GROUP, LLC
  52. Position the coolant bottle (1) and securely tighten the retaining bolts (2).
  53. Install the Power Distribution Center (PDC) mounting bracket.
  54. Install the PDC. Refer to CENTER, POWER DISTRIBUTION (PDC), DESCRIPTION .
  55. Position the wire harness and secure to the right hand inner fender panel.
  56. Install the cooling fan. Refer to FAN, COOLING, INSTALLATION .
    GC0170081Courtesy of CHRYSLER GROUP, LLC
  57. Position the oil cooler hose and Install oil cooler hose clamp (2).
  58. Position the upper radiator hose and install the upper radiator hose clamp (1).
    GC0080264Courtesy of CHRYSLER GROUP, LLC
  59. Install the strut tower support (6) and tighten the bolts to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  60. Install the cowl panel cover (1). Refer to COVER, COWL PANEL, INSTALLATION .
  61. Install a NEW  engine oil filter and fill the crankcase with the specified type and amount of engine oil. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
  62. Fill the cooling system with the specified type and amount of engine coolant. Refer to COOLANT SYSTEM AIR EVACUATION .
    GC0148445Courtesy of CHRYSLER GROUP, LLC
  63. Install the engine covers (1) onto the ball studs.
  64. Connect the negative battery cable.
  65. Start the engine and inspect for leaks.
NOTE:

The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components.

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