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3.6L Engine (Service Information): Installation: Installation

Fig 1: Upper Intake Manifold & Bolts
GC0144183Courtesy of CHRYSLER LLC
NOTE:

If installing a replacement engine, transfer components such as engine mount brackets, block heater, accessories, heater hoses and tubes to the replacement engine.

  1. If required, remove the upper intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL .
    Fig 2: Driver Side Engine Lifting Bracket & Bolts
    GC0144309Courtesy of CHRYSLER LLC
  2. Install the Driver Side Engine Lifting Bracket (special tool #10242-1, Brackets, Engine Lifting, Left Side) (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 3: Passenger Side Engine Lifting Bracket & Bolts
    GC0144310Courtesy of CHRYSLER LLC
  3. Install the Passenger Side Engine Lifting Bracket (special tool #10242-2, Brackets, Engine Lifting, Right Side) (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 4: Lifting Sling, Engine Lifting Brackets & Engine Hoist
    GC0144311Courtesy of CHRYSLER 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. Reposition the starter wire harness and the main wire harness to the rear of the engine compartment.
    Fig 5: Left Engine Mount Isolator & Upper Retaining Nut
    GC0144470Courtesy of CHRYSLER LLC
    NOTE:

    Left engine mount shown in illustration, right engine mount similar.

  6. Position the engine in the vehicle while aligning the two locator dowels into the transmission housing.
  7. Align the tab on the isolators (3) with the notch in the engine mount brackets (2) and lower the engine so the weight is resting on the isolators.
  8. Install the left and right engine mount nuts (1) and tighten to 61 N.m (45 ft.lbs.).
    Fig 6: Left Intake Manifold Support Brackets & Retaining Bolts
    GC0144406Courtesy of CHRYSLER LLC
  9. Remove the engine lifting brackets and install the LH upper intake manifold support brackets (1). Loosely install the stud bolts (2).
    Fig 7: Starter Wire Harness Retainers, Main Wire Harness Retainer & Manifold Support Bracket Retainers
    GC0144415Courtesy of CHRYSLER LLC
  10. Route the main wire harness and starter wire harness on the engine.
  11. Engage two starter wire harness retainers (1) to the upper intake manifold support brackets.
  12. Engage one main wire harness retainer (3) to the left cylinder head cover and two retainers (2) to the upper intake manifold support brackets.
    Fig 8: ECT Sensor Connector, CMP Sensor & Main Wire Harness Retainers
    GC0144416Courtesy of CHRYSLER LLC
  13. Connect the Engine Coolant Temperature (ECT) sensor connector (3).
  14. Connect the left Camshaft Position (CMP) sensor (5).
  15. Engage one main wire harness retainer (2) to the cylinder head cover and one main wire harness retainer (4) to the cylinder head cover mounting stud.
  16. Engage the main wire harness retainer (1) to the rear of the lower intake manifold.
    Fig 9: Main Wire Harness Retainer & Connector
    GC0144408Courtesy of CHRYSLER LLC
  17. Connect the electrical connector (1) to the right Camshaft Position (CMP) sensor.
  18. Engage the main wire harness retainer (2) to the right cylinder head cover mounting stud.
    Fig 10: Main Wire Harness Retainers At Right Cylinder Head Cover
    GC0144409Courtesy of CHRYSLER LLC
  19. Engage four main wire harness retainers (1) to the right cylinder head cover.
    Fig 11: Variable Valve Timing Solenoid Connectors & Harness Retainers
    GC0144413Courtesy of CHRYSLER LLC
  20. Connect the electrical connectors (2) to the variable valve timing solenoids on the right cylinder head.
  21. Engage two starter wire harness retainers (1) to the right cylinder head cover.
  22. Engage the starter harness to main harness retainer (3).
    Fig 12: Wire Harness Retainers, Oil Pump Solenoid Electrical Connector & Ground Strap
    GC0144414Courtesy of CHRYSLER LLC
  23. Connect the oil pump solenoid electrical connector (2).
  24. Engage four wire harness retainers (1).
  25. Install the ground strap (3) to the right engine mount bracket.
    Fig 13: Transmission-To-Engine Oil Pan Bolts
    GC0144171Courtesy of CHRYSLER LLC
  26. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
  27. Install four transmission to engine oil pan bolts (1). Tighten the bolts to 55 N.m (41 ft. lbs.).
    Fig 14: Rubber Plugs
    GC0144505Courtesy of CHRYSLER LLC
  28. Install two rubber plugs (1) covering the rear oil seal retainer flange bolts.
    Fig 15: Side Engine-To-Transmission Bolt, Transmission Dust Shield Retaining Bolt & Dust Shield
    GC0144170Courtesy of CHRYSLER LLC
  29. Install the side engine to transmission bolt (1). Tighten the bolt to 55 N.m (41 ft. lbs.).
  30. Install the torque converter dust shield (3) with the bolt (2). Tighten the bolt to 12 N.m (106 in. lbs.).
    Fig 16: Crossmember Brace & Bolts
    GC0145662Courtesy of CHRYSLER LLC
    NOTE:

    If equipped with AWD, the rear of the engine must be lowered in order to access the upper transmission to engine bolts.

  31. If equipped with AWD, support the transmission with a suitable jack, remove three crossmember brace bolts (1), six crossmember bolts (2) and adjust the jack to lower the rear of the engine.
    Fig 17: Upper Transmission Engine Bolts
    GC0145658Courtesy of CHRYSLER LLC
  32. Install the four upper transmission to engine bolts (1). Tighten the bolts to 55 N.m (41 ft. lbs.).
    Fig 18: Transmission Fluid Level Indicator Tube & Bolt
    GC0144412Courtesy of CHRYSLER LLC
  33. Install the bolt (1) securing the transmission fluid level indicator tube (2) to the transmission housing and tighten to 12 N.m (106 in. lbs.).
    Fig 19: Engine Injection/Ignition Harness & Engine Oil Pressure/Temperature Harness
    GC0144404Courtesy of CHRYSLER LLC
  34. Connect the main harness to the engine injection/ignition harness (1) at the rear of the left cylinder head.
  35. Connect the main harness to the engine oil pressure/temperature harness (2) at the rear of the left cylinder head.
    Fig 20: Crossmember Brace & Bolts
    GC0145662Courtesy of CHRYSLER LLC
  36. If equipped with AWD, raise the rear of the engine, reinstall six crossmember bolts (2) and three crossmember brace bolts (1). Tighten all bolts to 55 N.m (41 ft. lbs.).
    Fig 21: Torque Converter Bolt
    GC0144169Courtesy of CHRYSLER LLC
  37. Rotate the crankshaft in a clockwise direction and install the six torque converter bolts (1) through the starter mounting. Tighten the bolts to 42 N.m (31 ft. lbs.).
    Fig 22: Transmission Cooler Line Retainer
    GC0145014Courtesy of CHRYSLER LLC
  38. Clip the transmission cooler line retainer (1) to the oil pan flange.
    Fig 23: Wire Harness Retainers
    GC0144417Courtesy of CHRYSLER LLC
  39. Engage the starter wire harness retainer (2) and the main wire harness retainer (1) to the engine block.
  40. Install the starter. Refer to STARTER, INSTALLATION .
    Fig 24: Main Wire Harness Retainers & CKP Sensor
    GC0144418Courtesy of CHRYSLER LLC
  41. Connect the power cord to the engine block heater (if equipped).
  42. Connect the main wire harness to the Crankshaft Position (CKP) sensor (3).
  43. Engage one main wire harness retainer (1) to the engine block and one main wire harness retainer (2) to the right engine mounting bracket.
    Fig 25: CKP Sensor Heat Shield
    GC0144496Courtesy of CHRYSLER LLC
  44. Position the heatshield (1) over the crankshaft position (CKP) sensor.
    Fig 26: Front Axle & Axle Bracket
    GC0145633Courtesy of CHRYSLER LLC
  45. If equipped with AWD, install the front axle (1). Refer to INSTALLATION .
    Fig 27: Transfer Case Vent Hose Retainer & Upper Intake Manifold Support Bracket
    GC0145661Courtesy of CHRYSLER LLC
  46. Lower the vehicle.
  47. If equipped with AWD, engage the transfer case vent hose retainer (1) to the upper intake manifold support bracket (2).
    Fig 28: Heater Core Supply Tube Support Bracket & Retaining Bolt
    GC0144401Courtesy of CHRYSLER LLC
  48. Install the heater core supply tube (1) with one bolt (2) tightened to 12 N.m (106 in. lbs.).
    Fig 29: Oil Level Indicator & Retaining Bolt
    GC0144400Courtesy of CHRYSLER LLC
  49. Install the oil level indicator (2) with bolt (1) tightened 12 N.m (106 in. lbs.).
    Fig 30: A/C Compressor, Nut, Stud & Three Bolts
    GC0144012Courtesy of CHRYSLER LLC
  50. Install the A/C compressor (2) with three bolts (1) tightened to 25 N.m (18 ft. lbs.).
    Fig 31: Heater Core Return Hose, Heater Core Return Tube & Nut
    GC0145481Courtesy of CHRYSLER LLC
  51. Connect the heater core return hose (1).
    Fig 32: Lower Radiator Hose
    GC0145659Courtesy of CHRYSLER LLC
  52. Install the lower radiator hose (1) to the engine coolant pump housing.
    Fig 33: Upper Radiator Hose
    GC0144173Courtesy of CHRYSLER LLC
  53. Install the upper radiator hose (1) to the engine thermostat housing.
    Fig 34: Variable Valve Timing Solenoid Connectors & Wire Harness Retainers
    GC0144410Courtesy of CHRYSLER LLC
  54. Connect the electrical connectors (2) to the left variable valve timing solenoids.
  55. Engage two starter wire harness retainers (1) to the left cylinder head cover.
    Fig 35: A/C Compressor Electrical Connector & Wire Harness Retainer
    GC0144411Courtesy of CHRYSLER LLC
  56. Connect the A/C compressor electrical connector (1) and Engage the wire harness retainer (2) to the A/C compressor discharge line.
    Fig 36: Engine Mount Heatshield & Bolts
    GC0145667Courtesy of CHRYSLER LLC
    NOTE:

    Left engine mount shown in illustration, right engine mount similar.

  57. Install the engine mount heatshield (2) to both the left and right engine mounts with two bolts (1) tightened to 12 N.m (106 in. lbs.).
    Fig 37: Right Upstream Oxygen Electrical Sensor Connector, Down Pipe Flanges & Bolts
    GC0144419Courtesy of CHRYSLER LLC
    NOTE:

    Right catalytic converter shown in illustration, left catalytic converter similar.

  58. Install the right and left catalytic converters (2) onto the partially installed lower catalytic converter flange bolts (3).
  59. Install the upper catalytic converter flange bolts (1) and tighten all M8 bolts to 23 N.m (17 ft. lbs.).
  60. Connect the right and left upstream oxygen sensor connectors (4) to the main wire harness.
    Fig 38: Idler Pulley, Tensioner Arm, Belt, Idler, Tensioner & Belt
    GC0144013Courtesy of CHRYSLER LLC
  61. Install the generator (1). Refer to GENERATOR, INSTALLATION .
  62. Install the accessory drive belt (3). Refer to BELT, SERPENTINE, INSTALLATION .
    Fig 39: Cooling Fan Module Components
    GC0144321Courtesy of CHRYSLER LLC
  63. Install the cooling fan module. Refer to FAN, COOLING, INSTALLATION .
    Fig 40: Fuel Supply Hose At Underbody Fuel Supply Tube
    GC0144399Courtesy of CHRYSLER LLC
  64. Connect the fuel supply hose (1) to the underbody fuel tube (2). Refer to FITTING, QUICK CONNECT, STANDARD PROCEDURE .
    Fig 41: Transmission Breather Hose, Make-Up Air Tube & Clips
    GC0144423Courtesy of CHRYSLER LLC
  65. Install the make-up air tube (3) to the left cylinder head cover and engage the clips (1) to the transmission breather hose (2).
    Fig 42: Upper Intake Manifold Bolt Tightening Sequence
    GC0144185Courtesy of CHRYSLER LLC
  66. Install the upper intake manifold and insulator. Refer to MANIFOLD, INTAKE, INSTALLATION .
    Fig 43: PCV Hose & PCV Valve
    GC0144191Courtesy of CHRYSLER LLC
  67. Install the PCV hose (1) to the PCV valve (2).
    Fig 44: Vapor Purge Tube & Fuel Purge Solenoid
    GC0145482Courtesy of CHRYSLER LLC
  68. Install the vapor purge tube (1) to the fuel purge solenoid (2). Refer to FITTING, QUICK CONNECT, STANDARD PROCEDURE .
    Fig 45: Heater Core Return Hose, Heater Core Return Tube & Nut
    GC0145481Courtesy of CHRYSLER LLC
  69. Install the nut (2) to the support bracket of the heater core return tube (3) and tighten to 12 N.m (106 in. lbs.).
    Fig 46: Heater Core Return Tube, Nut & Bolt
    GC0144395Courtesy of CHRYSLER LLC
  70. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
  71. Install the A/C compressor mounting stud (2) and tighten to 25 N.m (18 ft. lbs.).
  72. Install the nut (1) and bolt (4) to the support brackets of the heater core return tube (3). Tighten to 12 N.m (106 in. lbs.).
  73. If equipped, install the transfer case skid plate, the transmission skid plate, the front suspension skid plate and the front skid plate. Refer to UNDER BODY PROTECTION .
    Fig 47: Mounting Bracket, Bolts, Electrical Connector, Vacuum Pump, Locking Tab & Quick-Connect Type End
    GC0145468Courtesy of CHRYSLER LLC
  74. Lower the vehicle.
  75. Install the electric vacuum pump (4) and mounting bracket (1). Refer to PUMP, ELECTRIC VACUUM, INSTALLATION .
    Fig 48: Air Inlet Hose, Air Temperature (IAT) Sensor Connector & Clamps
    GC0145457Courtesy of CHRYSLER LLC
  76. Install the resonator (3) and the air cleaner body. Refer to BODY, AIR CLEANER, INSTALLATION .
    Fig 49: Engine Cover
    GC0145477Courtesy of CHRYSLER LLC
  77. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to Engine/Lubrication/OIL - Standard Procedure .
  78. Fill the cooling system. Refer to STANDARD PROCEDURE .
  79. Install the engine cover (1).
  80. Install the hood. Refer to HOOD, INSTALLATION .
  81. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
  82. 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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