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3.6L Engine (Service Information): Installation: Installation

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.

NOTE:

If installing a replacement engine, transfer any necessary components such as engine mount brackets, block heater, accessories, and wiring harness to the replacement engine.

  1. If required, remove the upper intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL .
    Fig 1: Driver Side Engine Lifting Bracket & Bolts
    GC0144309Courtesy of CHRYSLER GROUP, LLC
  2. Install the (special tool #2028010090, Lift Bracket, Engine-Left) (1) on the LH cylinder head with bolts (2) provided with the Engine Lifting Bracket. Tighten the bolts to 21 N.m (15 ft. lbs.).
    Fig 2: Passenger Side Engine Lifting Bracket & Bolts
    GC0144310Courtesy of CHRYSLER GROUP, LLC
  3. Install the (special tool #2028020090, Lift Bracket, Engine-Right) (1) on the RH cylinder head with bolts (2) provided with the Engine Lifting Bracket. Tighten the bolts to 21 N.m (15 ft. lbs.).
    Fig 3: Lifting Sling, Engine Lifting Brackets & Engine Hoist
    GC0144311Courtesy of CHRYSLER GROUP, LLC
  4. Position a load-leveling lifting sling (2), such as OTC® 4305 Engine Load Leveler or equivalent, between the engine lifting brackets (3) and an engine hoist (1).
  5. Position the engine in the vehicle while aligning the two locator dowels into the transmission housing.
    Fig 4: Left Engine Mount Nut
    GC0173710Courtesy of CHRYSLER GROUP, LLC
  6. Align the tab on the isolators with the notch in the engine mount brackets and lower the engine so the weight is resting on the isolators.
  7. Install the left engine mount nut (1) and tighten to the proper specification. Refer to TORQUE SPECIFICATIONS .
    Fig 5: Right Engine Mount Nut
    GC0173579Courtesy of CHRYSLER GROUP, LLC
  8. Install the right engine mount nut (1) and tighten to the proper specification. Refer to TORQUE SPECIFICATIONS .
    Fig 6: Lifting Sling, Engine Lifting Brackets & Engine Hoist
    GC0144311Courtesy of CHRYSLER GROUP, LLC
  9. Remove the load-leveling lifting sling (2), such as OTC® 4305 Engine Load Leveler or equivalent, from the engine lifting brackets (3) and the engine hoist (1).
    Fig 7: Passenger Side Engine Lifting Bracket & Bolts
    GC0144310Courtesy of CHRYSLER GROUP, LLC
  10. Remove the passenger side engine lifting bracket bolts (2) from the RH cylinder head and remove the lift bracket (1).
    Fig 8: Driver Side Engine Lifting Bracket & Bolts
    GC0144309Courtesy of CHRYSLER GROUP, LLC
  11. Remove the driver side engine lifting bracket bolts (2) and remove the lift bracket (1).
    Fig 9: Transmission To Engine Oil Pan Bolts
    GC0173659Courtesy of CHRYSLER GROUP, LLC
  12. Install four transmission to engine oil pan bolts (1) and tighten to the proper specification. Refer to TORQUE SPECIFICATIONS .
    Fig 10: Rubber Plugs Covering Rear Oil Seal Retainer Flange Bolts
    GC0173609Courtesy of CHRYSLER GROUP, LLC
  13. Install two rubber plugs (1) covering the rear oil seal retainer flange bolts.
    Fig 11: Upper Transmission To Engine Bolts
    GC0173677Courtesy of CHRYSLER GROUP, LLC
  14. Install the four upper transmission to engine bolts (1) and tighten to the proper specification. Refer to TORQUE SPECIFICATIONS .
    Fig 12: Side Engine To Transmission Bolt
    GC0173593Courtesy of CHRYSLER GROUP, LLC
  15. Install the side engine to transmission bolt (1) and tighten to the proper specification. Refer to TORQUE SPECIFICATIONS .
    Fig 13: Torque Converter Bolt
    GC0144169Courtesy of CHRYSLER GROUP, LLC
  16. Rotate the crankshaft in a clockwise direction and install the six torque converter bolts (1) through the starter mounting and tighten to the proper specification. Refer to TORQUE SPECIFICATIONS .
    Fig 14: Torque Converter Dust Shield & Fastener
    GC0173680Courtesy of CHRYSLER GROUP, LLC
  17. Install the torque converter dust shield (1) with the bolt and tighten to the proper specification. Refer to TORQUE SPECIFICATIONS .
  18. Connect the power cord to the engine block heater (if equipped).
    Fig 15: O2 Sensor Wire Harness Bracket & Coolant Shut Off Valve Wire Harness Connector
    GC0173693Courtesy of CHRYSLER GROUP, LLC
  19. Install the oxygen sensor wire harness bracket (1) and position the harness with the engine.
  20. Connect the wire harness connector to the coolant shut off valve (2).
    Fig 16: Wire Harness Connector & Retainers
    GC0173570Courtesy of CHRYSLER GROUP, LLC
  21. Engage the wire harness retainers onto the transmission (2).
  22. Connect the wire harness connector (1) to the transmission.
    Fig 17: Transmission Cooler Line Fastener & Retainer
    GC0173586Courtesy of CHRYSLER GROUP, LLC
  23. Install the transmission cooler line fastener to the transmission (1) and engage the retainer (2) to the upper oil pan flange.
    Fig 18: Right Engine Mount Heat Shield Bolts
    GC0173740Courtesy of CHRYSLER GROUP, LLC
  24. Install the bolts (1) and the engine mount heat shield onto the right engine mount then tighten to the proper specification. Refer to TORQUE SPECIFICATIONS .
  25. Install the ground strap to the right engine mount bracket.
    Fig 19: Left Engine Mount Heat Shield Bolts
    GC0173741Courtesy of CHRYSLER GROUP, LLC
  26. Install the bolts (1) and the engine mount heat shield onto the left engine mount then tighten to the proper specification. Refer to TORQUE SPECIFICATIONS .
  27. Install the starter. Refer to STARTER, INSTALLATION .
  28. If equipped with AWD, install the front axle. Refer to INSTALLATION .
  29. Install both left and right catalytic converters. Refer to CONVERTER, CATALYTIC, INSTALLATION .
    Fig 20: Positive Starter And Alternator Cable & Wire Harness Retaining Clips
    GC0173705Courtesy of CHRYSLER GROUP, LLC
  30. Position the wire harness and engage the wire harness retaining clips (2).
  31. Connect the positive (1) starter and alternator cable.
    Fig 21: Wire Harness Connector, Wire Harness Retaining Clips & Nut
    GC0173723Courtesy of CHRYSLER GROUP, LLC
  32. Position the wire harness just below the PCM, on the right side frame rail and engage the wire harness retaining clips (2).
  33. Install the ground cable nut (3) and tighten to the proper specification. Refer to TORQUE SPECIFICATIONS .
  34. Connect the wire harness connector (1).
    Fig 22: PCM Wire Harness Connector & Wire Harness Retaining Clips
    GC0173731Courtesy of CHRYSLER GROUP, LLC
  35. Connect the wire harness connector (1) to the Powertrain Control Module (PCM).
  36. Engage the wire harness retaining clips (2).
    Fig 23: Oil Dipstick & Tube
    GC0173711Courtesy of CHRYSLER GROUP, LLC
  37. Install the oil level indicator (1).
  38. Install the cooling fan module. Refer to FAN, COOLING, INSTALLATION .
  39. Install the pressurized coolant bottle. Refer to BOTTLE, PRESSURIZED COOLANT, INSTALLATION .
    Fig 24: Coolant Bottle Inlet Hose
    GC0173782Courtesy of CHRYSLER GROUP, LLC
  40. Remove the coolant bottle inlet hose (1).
    Fig 25: Lower Radiator Hose
    GC0173784Courtesy of CHRYSLER GROUP, LLC
  41. Install the lower radiator hose (1) to the engine coolant pump housing.
    Fig 26: Upper Radiator Hose
    GC0173605Courtesy of CHRYSLER GROUP, LLC
  42. Install the upper radiator hose (1) to the engine thermostat housing.
    Fig 27: Heater Inlet Hose At Coolant Crossover & Heater Inlet Tube Assembly
    GC0173792Courtesy of CHRYSLER GROUP, LLC
  43. Install the heater inlet hose onto the coolant crossover (1) and position the heater inlet tube assembly (2).
    Fig 28: Heater Core Return Hose At Water Pump Bypass, Retaining Bolts At Engine Block & Cylinder Head
    GC0173642Courtesy of CHRYSLER GROUP, LLC
  44. Connect the return hose to the engine oil cooler and position the tube assembly to the engine.
  45. Install the retaining bolts to the engine block (2) and cylinder head (3) then tighten to the proper specification. Refer to TORQUE SPECIFICATIONS .
  46. Install the heater core return hose to the water pump bypass (1).
    Fig 29: Fuel Supply Hose At Fuel Rail
    GC0173709Courtesy of CHRYSLER GROUP, LLC
  47. Connect the fuel supply hose to the fuel rail. Refer to FITTING, QUICK CONNECT, STANDARD PROCEDURE .
  48. Install the A/C compressor. Refer to COMPRESSOR, A/C, INSTALLATION .
  49. Install the electric vacuum pump and mounting bracket. Refer to PUMP, ELECTRIC VACUUM, INSTALLATION .
  50. Install the Exhaust Gas Recirculation (EGR) cooler. Refer to COOLER, EXHAUST GAS RECIRCULATION (EGR), INSTALLATION .
  51. Install the upper intake manifold and insulator. Refer to MANIFOLD, INTAKE, INSTALLATION .
  52. Install the resonator and the air cleaner body Refer to BODY, AIR CLEANER, INSTALLATION .
  53. If equipped, install the transfer case skid plate, the transmission skid plate, the front suspension skid plate and the front skid plate. Refer to PLATE, SKID, FRONT, INSTALLATION , PLATE, SKID, FRONT SUSPENSION, INSTALLATION , PLATE, SKID, FUEL TANK, INSTALLATION , PLATE, SKID, TRANSMISSION, INSTALLATION and PLATE, SKID, TRANSFER CASE, INSTALLATION .
  54. Install the cowl extension panel. Refer to SILENCER, COWL EXTENSION, INSTALLATION .
  55. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to STANDARD PROCEDURE .
  56. Fill the cooling system. Refer to STANDARD PROCEDURE .
  57. Install the hood. Refer to HOOD, INSTALLATION .
  58. Connect the negative battery cable.
  59. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to STANDARD PROCEDURE .
    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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