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Section 2 (6.4L Engine (Service Information)): Removal

WARNING: This page is about a different variant/trim than selected.
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.

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.

  1. Disconnect and isolate the negative battery cable.
  2. Remove the front skid plate. Refer to REMOVAL .
  3. Remove the transmission skid plate. Refer to PLATE, SKID, TRANSMISSION .
  4. Drain the cooling system. Refer to DRAINING .
  5. Drain the engine oil. Refer to STANDARD PROCEDURE - ENGINE OIL SERVICE  .
  6. Recover the A/C refrigerant. Refer to REFRIGERANT SYSTEM RECOVERY .
  7. Remove the air cleaner housing assembly. Refer to BODY, AIR CLEANER, REMOVAL .
    GC0148445Courtesy of CHRYSLER GROUP, LLC
  8. Lift the engine cover retaining grommets off the ball studs and remove the engine covers (1).
  9. Perform the fuel system pressure release procedure. Refer to FUEL SYSTEM PRESSURE RELEASE .
  10. Remove the hood. Refer to HOOD, REMOVAL .
  11. Remove the cowl panel cover and support. Refer to COVER, COWL PANEL, REMOVAL .
  12. Remove the strut tower support.
    GC0148460Courtesy of CHRYSLER GROUP, LLC
  13. Remove the upper radiator hose clamp (1) and remove the upper radiator hose (2).
  14. Remove the oil cooler hose clamp (3) and remove the oil cooler hose (4).
    GC0144611Courtesy of CHRYSLER GROUP, LLC
  15. Remove the heater tube retaining bolt (1).
  16. Remove the coolant temperature sensor electrical connector (2).
  17. Lift the heater tube (3) out of the water pump.
    GC0148461Courtesy of CHRYSLER GROUP, LLC
  18. Disconnect the camshaft position sensor electrical connector (1).
    GC0080075Courtesy of CHRYSLER GROUP, LLC
  19. Remove all ignition coil electrical connectors (1) and position the harness aside.
  20. Remove the intake manifold. Refer to REMOVAL  .
  21. Remove the Variable Valve Timing Solenoid (VVTS). Refer to SOLENOID, VARIABLE VALVE TIMING (VVTS), INSTALLATION .
    GC0080072Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The ignition capacitor (2) is located near the left rear corner of the intake manifold (3).

  22. Remove the ignition capacitor (1) electrical connector (2).
  23. Remove the ground wires from the rear of each cylinder head.
    CAUTION:

    Do not let the tensioner arm snap back to the freearm position, severe damage may occur to the tensioner.

    GC0144483Courtesy of CHRYSLER GROUP, LLC
  24. Rotate the accessory drive belt tensioner (8) clockwise until it contacts the stop and remove the accessory drive belt (4), then slowly rotate the tensioner into the freearm position.
    GC0148443Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    It is not necessary to disconnect power steering pump hoses from power steering pump for power steering pump removal.

  25. Remove the three power steering pump (4) mounting bolts (2) through the access holes in the pulley (3) and position the pump aside.
  26. Disconnect the up stream O2 sensor electrical connectors.
  27. Remove the cooling fan. Refer to 3.6L/5.7L/6.4L .
  28. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
    GC0148457Courtesy of CHRYSLER GROUP, LLC
  29. Disconnect the cooling lines (3 and 4) at the oil cooler (2).
    GC0095212Courtesy of CHRYSLER GROUP, LLC
  30. Remove the lower radiator hose (1).
  31. Remove the front driveshaft. Refer to REMOVAL .
  32. Remove the both catalytic converters from the vehicle. Refer to CONVERTER, CATALYTIC, REMOVAL .
  33. Remove the starter. Refer to 6.4L .
    GC0146313Courtesy of CHRYSLER GROUP, LLC
  34. Position the transmission crossmember (1) into position and loosely install the bolts (2).
  35. Lower the transmission into position onto the crossmember.
    GC0144624Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Two knock sensors are used. Each sensor is bolted to the outside of the engine block below the exhaust manifold.

  36. Remove the heat shield from the right side knock sensor (shield snaps on/off sensor).
  37. Disconnect the knock sensor electrical connectors (3).
    GC0095565Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

  38. Remove the CKP sensor electrical connector (1).
    GC0081819Courtesy of CHRYSLER GROUP, LLC
  39. Remove the transmission inspection cover retaining bolt (2) and remove the inspection cover (1).
    GC0095570Courtesy of CHRYSLER GROUP, LLC
  40. Automatic transmission equipped vehicles, rotate the crankshaft in clockwise direction until the torque converter bolts (1) are accessible and remove the flexplate to torque converter bolts (1).
    GC0081820Courtesy of CHRYSLER GROUP, LLC
  41. Remove the oil pan to transmission bolts (1).
    CAUTION:

    While carefully separating the engine from the transmission and removing the engine from the vehicle, constant checks must be made to ensure no damage to other components or wiring harnesses occur throughout the removal procedure.

    GC0081821Courtesy of CHRYSLER GROUP, LLC
  42. Disconnect the transmission oil cooler lines from their retainers at the oil pan.
  43. Remove the transmission bell housing to engine block bolts (2).
  44. Remove the A/C compressor and position aside. Refer to COMPRESSOR, A/C, REMOVAL .
  45. Remove the generator. Refer to 6.4L .
    GC0095586Courtesy of CHRYSLER GROUP, LLC
  46. Remove the oil pressure sensor electrical connector (1).
    GC0095588Courtesy of CHRYSLER GROUP, LLC
  47. Remove the oil temperature sensor electrical connector (1).
    GC0095566Courtesy of CHRYSLER GROUP, LLC
  48. Remove the heater hoses (1, 2).
    GC0145991Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    It is not necessary to remove the hoses from the coolant bottle for coolant bottle removal.

  49. Remove the coolant bottle and position the coolant bottle (1) aside.
  50. Unfasten the wire harness mounted on the right hand inner fender panel and position aside.
    GC0144614Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Left side shown, right side similar.

  51. Remove both left/right engine mount heat shield (4) retaining nuts (3) and remove the heat shields.
  52. Remove both left/right engine mount to frame retaining bolts (2).
    GC0081822Courtesy of CHRYSLER GROUP, LLC
  53. Using a suitable jack, support the transmission.
    NOTE:

    Do not use air tools to install engine lift fixture.

  54. Install the engine lift fixture (special tool #8984C, Fixture, Engine Lifting) (2) and adapter (special tool #8984-UPD, Adapter, Engine Lift) (4).
  55. Using a suitable engine hoist, separate the engine from the transmission and remove the engine from the engine compartment.
  56. Secure the engine onto a suitable engine stand.
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