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Section 263 (3.6L Engine (Service Information) - 1500): Removal: Removal

WARNING: This page is about a different car, the 2013 RAM 1500. However, it is still accessible from the selected car via links, so may be relevant.
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.

  1. Perform the fuel pressure release procedure. Refer to FUEL DELIVERY, GAS, STANDARD PROCEDURE .
  2. Disconnect and isolate the battery negative cable.
  3. Drain the cooling system. Refer to STANDARD PROCEDURE .
  4. Evacuate the A/C system. Refer to PLUMBING, STANDARD PROCEDURE .
  5. With the help of an assistant, remove the hood from the vehicle

    Refer to HOOD, REMOVAL .

    NOTE:

    The engine cover is bonded to the air intake assembly. Do not attempt to separate them. The cover and intake must be removed as an assembly.

    Fig 1: IAT Sensor Electrical Connector
    GC0154633Courtesy of CHRYSLER GROUP, LLC
  6. Loosen the air intake clamp (1) at the throttle body.
  7. Disconnect the Intake Air Temperature (IAT) sensor (2).
    Fig 2: Breather Tube & Resonator
    GC0154529Courtesy of CHRYSLER GROUP, LLC
  8. Remove the breather tube (1) from the resonator (2).
    Fig 3: Removing/Installing Air Filter Box Cover
    GC0154523Courtesy of CHRYSLER GROUP, LLC
  9. Remove the air filter housing cover (2) and lower housing assembly (4).
    Fig 4: Removing/Installing Electric Cooling Fan
    GC0154428Courtesy of CHRYSLER GROUP, LLC
  10. Remove the cooling fan (3). Refer to FAN, COOLING, ELECTRIC, REMOVAL .
    Fig 5: Upper Intake Manifold & Fasteners
    GC0154013Courtesy of CHRYSLER GROUP, LLC
  11. Remove the upper intake manifold (2) and insulator

    Refer to MANIFOLD, INTAKE, REMOVAL  .

    Fig 6: Left Rear Upper Intake Manifold Support Bracket & Studbolts
    GC0154056Courtesy of CHRYSLER GROUP, LLC
  12. Remove the two stud bolts (2) and remove the left rear upper intake manifold support bracket (1).
    Fig 7: Mounting Bracket, Bolts, Electrical Connector, Vacuum Pump, Locking Tab & Quick-Connect Type End
    GC0145468Courtesy of CHRYSLER GROUP, LLC
  13. Remove the vacuum pump and bracket. Refer to PUMP, ELECTRIC VACUUM, REMOVAL .
    Fig 8: Fuel Rail Pressure Sensor
    GC0154617Courtesy of CHRYSLER GROUP, LLC
  14. Disconnect the fuel pressure sensor electrical connector (3).
  15. Disconnect the fuel supply hose (2) at the in-line fuel pressure sensor. Refer to FITTING, QUICK CONNECT, STANDARD PROCEDURE .
    Fig 9: Identifying Drive Belt (3.6L Engine)
    GC0154511Courtesy of CHRYSLER GROUP, LLC
  16. Remove the accessory drive belt (1). Refer to BELT, SERPENTINE, REMOVAL .
    Fig 10: Variable Valve Timing Solenoid Connectors & Wire Harness Retainers
    GC0144410Courtesy of CHRYSLER GROUP, LLC
    17. NOTE:

    Mark and disconnect the left bank variable valve timing solenoid connectors (2) with a paint pen or equivalent so that they may be reinstalled in their original locations.

  18. Remove the wire harness retainers (1) from the left cylinder head cover.
  19. Disconnect the left side upstream O2 sensor wiring harness connector.
    Fig 11: Variable Valve Timing Solenoid Connectors & Harness Retainers
    GC0144413Courtesy of CHRYSLER GROUP, LLC
  20. Mark and disconnect the right intake variable valve timing solenoid electrical connector (6).
  21. Remove the wire harness retainers (1 and 3) from the right cylinder head cover.
  22. Disconnect the right side upstream O2 sensor wiring harness connector.
    Fig 12: Field Circuit Connector And B+ Terminal Cable
    GC0146042Courtesy of CHRYSLER GROUP, LLC
  23. Disconnect the field circuit connector (3) from the generator.
  24. Remove the B+ terminal cable (2) from the generator stud.
    Fig 13: Engine Injection/Ignition Harness, Ignition Coil Electrical Connectors, Retainers, Camshaft Position (CMP) Sensor Connector & Fuel Injector Electrical Connectors
    GC0154029Courtesy of CHRYSLER GROUP, LLC
  25. Disconnect the main harness from the engine injection/ignition harness (1).
  26. Disconnect three fuel injector electrical connectors (5).
  27. Disconnect three ignition coil electrical connectors (2).
  28. Disconnect the electrical connector (4) from the right Camshaft Position (CMP) sensor.
  29. Remove the three main wire harness retainers (3) from the right cylinder head cover.
    Fig 14: ECT Sensor Connector, CMP Sensor & Main Wire Harness Retainers
    GC0144416Courtesy of CHRYSLER GROUP, LLC
  30. Disconnect the left Camshaft Position (CMP) sensor (5).
  31. Remove the wire harness retainers (1, 2, and 4) from the cylinder head cover mounting stud.
    Fig 15: Ground Strap, Bolt & Connectors
    GC0154454Courtesy of CHRYSLER GROUP, LLC
  32. Remove the ground straps from the back of the cylinder heads.
  33. Disconnect the ignition coil capacitor electrical connectors (2).
    Fig 16: A/C Discharge & Liquid Lines
    GC0089589Courtesy of CHRYSLER GROUP, LLC
  34. Disconnect the A/C compressor electrical connector.
  35. Remove the A/C lines (2) at the condenser (1).
    Fig 17: Lower Coupling At Gear
    GC0131140Courtesy of CHRYSLER GROUP, LLC
  36. Remove the lower intermediate shaft coupler (1) at the steering gear (2).
    Fig 18: Removing/Installing A/C Compressor
    GC0154471Courtesy of CHRYSLER GROUP, LLC
  37. Remove the A/C compressor (2).
    Fig 19: 3.6L Engine Block Heater & Cylinder Block
    GC0144482Courtesy of CHRYSLER GROUP, LLC
  38. Disconnect the power cord from the engine block heater (if equipped).
  39. Partially raise the vehicle.
  40. If required, drain the engine oil

    Refer to LUBRICATION/OIL - STANDARD PROCEDURE  .

    NOTE:

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

    Fig 20: Upstream & Downstream Oxygen Sensors & Bolts
    GC0153991Courtesy of CHRYSLER GROUP, LLC
  41. Remove the front wheels.
  42. Remove the right and left upper catalytic converter bolts (2).
  43. Disconnect the right and left side downstream oxygen sensor (1) connectors from the main wire harness.
    Fig 21: Coolant Heater Tubes-To-Cylinder Head Bolts And Oil Indicator
    GC0154427Courtesy of CHRYSLER GROUP, LLC
  44. Remove the bolts (1) that secure the coolant heater tubes to the cylinder head.
  45. Remove the oil indicator (2).
  46. Raise the vehicle.
    NOTE:

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

    Fig 22: Y-Pipe Flange Nuts
    GC0154669Courtesy of CHRYSLER GROUP, LLC
  47. Remove the left and right side catalytic converter to Y-pipe (1) flange nuts (2).
  48. Remove the catalytic converters from the vehicle.
  49. Loosen the catalytic converter flange bolts.
    Fig 23: Removing/Installing Starter
    GC0154351Courtesy of CHRYSLER GROUP, LLC
  50. Remove the starter. Refer to STARTER, REMOVAL .
    Fig 24: Starter Solenoid Wiring Harness-To-Engine Block Bolts
    GC0154627Courtesy of CHRYSLER GROUP, LLC
  51. Remove the bolts (1) that secures the starter solenoid wiring harness (2) to the engine block, and position aside.
    Fig 25: Identifying Engine Coolant Temperature Sensor (3.6L)
    GC0154593Courtesy of CHRYSLER GROUP, LLC
  52. Slide the heat shield cover (1) from the temperature sensor (2).
  53. Disconnect the Engine Coolant Temperature (ECT) sensor connector.
    Fig 26: Removing/Installing Battery Ground Cable
    GC0154502Courtesy of CHRYSLER GROUP, LLC
  54. Remove the battery ground cable (1) from the engine block.
    Fig 27: Stop/Start Solenoid, Electrical Connector And Battery Positive Cable
    GC0154560Courtesy of CHRYSLER GROUP, LLC
  55. Disconnect the stop/start solenoid (1) electrical connector (4).
  56. Remove the Battery positive cable (5) from the stop/start solenoid.
    Fig 28: Torque Converter Bolt
    GC0144169Courtesy of CHRYSLER GROUP, LLC
  57. Rotate the crankshaft in a clockwise direction until the torque converter bolts (1) are accessible through the starter mounting.
    Fig 29: Oil Pump Solenoid Electrical Connector & Wire Harness Retainers
    GC0154031Courtesy of CHRYSLER GROUP, LLC
  58. Remove the main wire harness retainer (4) from the engine block.
  59. Disconnect the oil pump solenoid electrical connector (1).
  60. Remove the wire harness retainer (2) from the engine block.
    Fig 30: CKP Sensor - 3.6L
    GC0154591Courtesy of CHRYSLER GROUP, LLC
  61. Remove the wire harness retainer from the oil level indicator tube (1).
  62. Remove the crankshaft positioning sensor electrical connector (3).
  63. Remove the wire harness retainers from the engine block (2).
    Fig 31: Disengaging Transmission Cooler Line Retainer
    GC0154006Courtesy of CHRYSLER GROUP, LLC
  64. Remove the transmission cooler line retainer (1) from the oil pan flange.
    Fig 32: Thermal Management Lines And Bolt
    GC0154446Courtesy of CHRYSLER GROUP, LLC
  65. Remove the bolt (2) that secures the thermal management lines (1) to the transmission bell housing.
  66. Remove the transmission heater hose from the thermal management line.
    Fig 33: Side Engine-To-Transmission Bolt, Transmission Dust Shield Retaining Bolt & Dust Shield
    GC0144170Courtesy of CHRYSLER GROUP, LLC
  67. Remove the bolt (2) and the torque converter dust shield (3).
  68. Remove the side engine to transmission bolt (1).
    Fig 34: Rubber Plugs & Transmission-To-Engine Oil Pan Bolts
    GC0154007Courtesy of CHRYSLER GROUP, LLC
  69. If equipped with an automatic transmission;
    • Remove two rubber plugs (1) covering the rear oil seal retainer flange bolts.
    • Remove four transmission to the engine oil pan bolts (2 and 3).
    Fig 35: Upper Transmission Engine Bolts
    GC0145658Courtesy of CHRYSLER GROUP, LLC
  70. Remove four upper transmission to engine bolts (1).
    Fig 36: Remove/Install Engine Mount, Heat Shield And Engine Bracket Bolts
    GC0154564Courtesy of CHRYSLER GROUP, LLC
  71. Remove the engine mount (6) heat shield (5).
  72. Loosen the outer engine bracket bolt (4) from the engine bracket.
  73. Remove the inner through engine bracket bolt (2).
    Fig 37: Engine Mount & Bolt
    GC0082897Courtesy of CHRYSLER GROUP, LLC
  74. 2WD vehicles, 

    Loosen the engine support bolt (3).

  75. Lower the vehicle.
    Fig 38: Upper Radiator Hose
    GC0144173Courtesy of CHRYSLER GROUP, LLC
  76. Remove the upper radiator hose (1) from the engine thermostat housing and position aside.
    Fig 39: Coolant Outlet Housing, Water Pump & Bolts
    GC0144267Courtesy of CHRYSLER GROUP, LLC
  77. Remove the heater line at the coolant crossover (1).
    Fig 40: Radiator Hose & Heater Hose
    GC0144271Courtesy of CHRYSLER GROUP, LLC
  78. Remove the heater hose (1) at the water pump and position aside.
  79. Remove the lower radiator hose (2) from the engine coolant pump housing and position aside.
    Fig 41: Driver Side Engine Lifting Bracket & Bolts
    GC0144309Courtesy of CHRYSLER GROUP, LLC
  80. 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 42: Passenger Side Engine Lifting Bracket & Bolts
    GC0144310Courtesy of CHRYSLER GROUP, LLC
  81. 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) from the Engine Lifting Bracket. Tighten the bolts to 21 N.m (15 ft. lbs.).
  82. Reposition the main wire harness to the rear of the engine compartment.

    Right engine mount shown in illustration, left engine mount similar.

  83. Support the transmission with a suitable jack.
    CAUTION:

    While slowly separating the engine from the vehicle, constant checks must be made to assure proper positioning and that no damage to other components or wiring harnesses occur during separation.

  84. Carefully remove the engine from the engine bay area.
  85. If required, remove the following components for installation on the replacement engine:
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