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Section 539 (3.6L Engine (Service Information) 1500): Installation: Installation

WARNING: This page is about a different car, the 2014 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.

NOTE:

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

Fig 1: Driver Side Engine Lifting Bracket & Bolts
GC0144309Courtesy of CHRYSLER GROUP, LLC
  1. 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 2: Passenger Side Engine Lifting Bracket & Bolts
    GC0144310Courtesy of CHRYSLER GROUP, LLC
  2. 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.).
  3. Reposition the main wire harness to the rear of the engine compartment.
    NOTE:

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

    Fig 3: Engine Mount Bolt
    GC0082897Courtesy of CHRYSLER GROUP, LLC
  4. 2WD Vehicle, 

    Position the engine mount (2) onto the engine support (1). Tighten the bolt (3) to 95 N.m (70 ft. lbs.).

    Fig 4: Engine Mount Bracket Bolts
    GC0154475Courtesy of CHRYSLER GROUP, LLC
  5. If removed, install the engine mount brackets. Tighten the bolts (1) to 61 N.m (45 ft. lbs.).
  6. Position the engine in the vehicle. Align the two outer engine mount bolts to the engine mount bracket (2).
    Fig 5: Remove/Install Engine Mount, Heat Shield And Engine Bracket Bolts
    GC0154564Courtesy of CHRYSLER GROUP, LLC
  7. Align the left and right engine mount isolators (6) within the frame mounting brackets and lower the engine so the weight is resting on the outer mounting bolts (4).
  8. Install the inner engine mount to bracket through bolt (2).
  9. Raise the vehicle.
  10. Tighten the left and right engine mount nuts (3) to 61 N.m (45 ft. lbs.).
  11. Install the engine mount heat shield (5). Tighten the nut to 12 N.m (106 in. lbs.).
    Fig 6: Upper Transmission Engine Bolts
    GC0145658Courtesy of CHRYSLER GROUP, LLC
  12. Install the four upper transmission to engine bolts (1). Tighten the bolts to 55 N.m (41 ft. lbs.).
    Fig 7: Rubber Plugs & Transmission-To-Engine Oil Pan Bolts
    GC0154007Courtesy of CHRYSLER GROUP, LLC
  13. Install four transmission to the engine oil pan bolts (2 and 3) and tighten to 55 N.m (41 ft. lbs.).
  14. Install two rubber plugs (1) covering the rear oil seal retainer flange bolts.
    Fig 8: Side Engine-To-Transmission Bolt, Transmission Dust Shield Retaining Bolt & Dust Shield
    GC0144170Courtesy of CHRYSLER GROUP, LLC
  15. Install the side engine to transmission bolt (1). Tighten the bolt to 55 N.m (41 ft. lbs.).
  16. Install the torque converter dust shield (3) with the bolt (2). Tighten the bolt to 12 N.m (106 in. lbs.).
    Fig 9: Engaging Transmission Cooler Line Retainer
    GC0154010Courtesy of CHRYSLER GROUP, LLC
  17. Install the transmission cooler line retainer (1) to the oil pan flange.
    Fig 10: Torque Converter Bolt
    GC0144169Courtesy of CHRYSLER GROUP, LLC
  18. If equipped with an automatic transmission, 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 11: Identifying Engine Coolant Temperature Sensor (3.6L)
    GC0154593Courtesy of CHRYSLER GROUP, LLC
  19. Connect the temperature sensor electrical connector (2).
  20. Reposition the temperature sensor heat shield cover (1).
    Fig 12: Removing/Installing Battery Ground Cable
    GC0154502Courtesy of CHRYSLER GROUP, LLC
  21. Install the battery ground (1) to the engine block. Tightened to 12 N.m (106 in. lbs.).
    Fig 13: Stop/Start Solenoid, Electrical Connector And Battery Positive Cable
    GC0154560Courtesy of CHRYSLER GROUP, LLC
  22. Install the battery positive cable (4) to the stop/start solenoid (1).
  23. Connect the stop/start solenoid electrical connector (4).
    Fig 14: Starter Solenoid Wiring Harness-To-Engine Block Bolts
    GC0154627Courtesy of CHRYSLER GROUP, LLC
  24. Install the starter solenoid wiring harness (2) loom bolts (1). Tighten the bolts to 12 N.m (106 in. lbs.).
    Fig 15: Removing/Installing Starter
    GC0154351Courtesy of CHRYSLER GROUP, LLC
  25. Install the starter (3). Refer to STARTER, INSTALLATION .
    Fig 16: Oil Pump Solenoid Electrical Connector & Wire Harness Retainers
    GC0154031Courtesy of CHRYSLER GROUP, LLC
  26. Connect the oil pump solenoid electrical connector (1).
    Fig 17: CKP Sensor - 3.6L
    GC0154591Courtesy of CHRYSLER GROUP, LLC
  27. Connect the crank shaft positioning sensor electrical connector (3).
  28. Install the wiring harness retainers (2).
  29. Install the transmission heater hose to the thermal management line.
    Fig 18: Thermal Management Lines And Bolt
    GC0154446Courtesy of CHRYSLER GROUP, LLC
  30. Install the thermal management line bracket (1) to the transmission bell housing. Tighten the bolt (2) to 12 N.m (106 in. lbs.).
    Fig 19: Y-Pipe Flange Nuts
    GC0154669Courtesy of CHRYSLER GROUP, LLC
  31. Position the catalytic convertor to the cylinder heads.
  32. Align the Y-pipe (1) to the catalytic convertor flanges. Tighten the flange nuts to 23 N.m (17 ft. lbs.).
  33. Partially lower the vehicle.
    Fig 20: Coolant Heater Tubes-To-Cylinder Head Bolts And Oil Indicator
    GC0154427Courtesy of CHRYSLER GROUP, LLC
  34. Align the heater line support braces to the right side cylinder head. Install the bolts (1) loose.
  35. Install the oil indicator tube (2) into the oil pan. Align the mounting tab to the heater line brace bolt. Tighten the bolts to 12 N.m (106 in. lbs.).
    NOTE:

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

    Fig 21: Upstream & Downstream Oxygen Sensors & Bolts
    GC0153991Courtesy of CHRYSLER GROUP, LLC
  36. Install the right and left catalytic converters upper bolts (2). Tighten the bolts to 37 N.m (27 ft. lbs.).
    Fig 22: Left Upstream Oxygen Sensor & Left Downstream Oxygen Sensor Electrical Connectors
    GC0154038Courtesy of CHRYSLER GROUP, LLC
  37. Connect the right and left upstream (1) and downstream (2) oxygen sensor connectors to the main wire harness.
  38. Lower the vehicle.
    Fig 23: Block Heater & Screw
    GC0144482Courtesy of CHRYSLER GROUP, LLC
  39. Connect the power cord to the engine block heater (if equipped).
  40. Lower the vehicle.
    Fig 24: A/C Compressor & Mounting Bolts
    GC0153970Courtesy of CHRYSLER GROUP, LLC
  41. Install the A/C compressor (2) onto the engine. Tighten bolts to 28 N.m (21 ft. lbs.).
  42. Connect the A/C compressor electrical connector (2).
    Fig 25: Lower Coupling AT Gear
    GC0131140Courtesy of CHRYSLER GROUP, LLC
  43. Align the lower intermediate shaft coupler (1) to the steering gear (2). Tighten the bolt to 49 N.m (36 ft. lbs.).
    Fig 26: Retainers, A/C Compressor Electrical Connector & Left Intake And Left Exhaust Variable Valve Timing Solenoid Electrical Connectors
    GC0154026Courtesy of CHRYSLER GROUP, LLC
  44. Route the main wire harness on the left side of the engine.
  45. Connect the left exhaust variable valve timing solenoid electrical connector (4).
  46. Connect the left intake variable valve timing solenoid electrical connector (3).
  47. Engage three wire harness retainers (1) to the left cylinder head cover.
    Fig 27: ECT Sensor Connector, CMP Sensor & Main Wire Harness Retainers
    GC0144416Courtesy of CHRYSLER GROUP, LLC
  48. Connect the left Camshaft Position (CMP) sensor (5).
  49. Engage the main wire harness retainers (1 and 2) to the cylinder head cover mounting stud.
    Fig 28: Engine Injection/Ignition Harness, Ignition Coil Electrical Connectors, Retainers, Camshaft Position (CMP) Sensor Connector & Fuel Injector Electrical Connectors
    GC0154029Courtesy of CHRYSLER GROUP, LLC
  50. Route the main wire harness on the right side of the engine.
  51. Connect the electrical connector (4) to the right Camshaft Position (CMP) sensor.
  52. Connect three fuel injector electrical connectors (5).
  53. Connect the main harness to the engine injection/ignition harness (1).
  54. Engage three main wire harness retainers (3) to the right cylinder head cover.
  55. Connect three ignition coil electrical connectors (2).
    Fig 29: Field Circuit, B+ Terminal Nut And Wire
    GC0146042Courtesy of CHRYSLER GROUP, LLC
  56. Install the B+ terminal to the generator stud (2). Tighten the nut (1) to 11 N.m (97 in. lbs.).
  57. Connect the field circuit connector (3) to the generator.
    Fig 30: Variable Valve Timing Solenoid Connectors & Harness Retainers
    GC0144413Courtesy of CHRYSLER GROUP, LLC
  58. Connect the right exhaust variable valve timing solenoid electrical connector (5).
  59. Connect the right intake variable valve timing solenoid electrical connector (6).
  60. Engage the wire harness retainers (1) to the cylinder head cover.
    Fig 31: Ground Strap, Bolt & Connectors
    GC0154454Courtesy of CHRYSLER GROUP, LLC
  61. Secure the ground to the rear of the cylinder heads. Tighten the bolt (2) tightened to 12 N.m (106 in. lbs.).
  62. Connect the electrical connector (3) to the ignition coil capacitors.
    Fig 32: Identifying Drive Belt (3.6L Engine)
    GC0154511Courtesy of CHRYSLER GROUP, LLC
  63. Install the accessory drive belt (1). Refer to BELT, SERPENTINE, INSTALLATION .
    Fig 33: Mounting Bracket, Bolts, Electrical Connector, Vacuum Pump, Locking Tab & Quick-Connect Type End
    GC0145468Courtesy of CHRYSLER GROUP, LLC
  64. Install the vacuum pump (4). Refer to PUMP, ELECTRIC VACUUM, INSTALLATION .
    Fig 34: Fuel Rail Pressure Sensor
    GC0154617Courtesy of CHRYSLER GROUP, LLC
  65. Connect the fuel supply hose (2) to the fuel pressure sensor.
  66. Install the fuel pressure sensor electrical connector (3).
    Fig 35: Intake Ports, Insulator & Alignment Posts
    GC0144184Courtesy of CHRYSLER GROUP, LLC
  67. Install the insulator (2) to the two alignment posts (3) on top of the LH cylinder head cover.
    Fig 36: Upper Intake Manifold Tightening Sequence
    GC0154022Courtesy of CHRYSLER GROUP, LLC
  68. Install the upper intake manifold and insulator. Refer to MANIFOLD, INTAKE, INSTALLATION  .
    Fig 37: Radiator Hose & Heater Hose
    GC0144271Courtesy of CHRYSLER GROUP, LLC
  69. Connect the heater core return hose (1) to the water pump.
  70. Install the lower radiator hose (2) to the engine coolant pump housing.
    Fig 38: Coolant Outlet Housing, Water Pump & Bolts
    GC0144267Courtesy of CHRYSLER GROUP, LLC
  71. Install the heater supply hose to the coolant crossover (1).
    Fig 39: Upper Radiator Hose
    GC0144173Courtesy of CHRYSLER GROUP, LLC
  72. Install the upper radiator hose (1) to the engine thermostat housing.
    Fig 40: A/C Discharge & Liquid Lines
    GC0089589Courtesy of CHRYSLER GROUP, LLC
  73. Install the A/C lines to the condenser (1). Tighten the nuts (2) to 23 N.m (17 ft. lbs.).
  74. Recharge the A/C system. Refer to PLUMBING, STANDARD PROCEDURE .
    Fig 41: Removing/Installing Air Filter Box Cover
    GC0154523Courtesy of CHRYSLER GROUP, LLC
  75. Install the air cleaner lower housing assembly (4).
    Fig 42: IAT Sensor Electrical Connector
    GC0154633Courtesy of CHRYSLER GROUP, LLC
  76. Position the air intake onto the throttle body. Hand tighten the clamp (1).
  77. Install the IAT sensor electrical connector (2)
    Fig 43: Breather Tube & Resonator
    GC0154529Courtesy of CHRYSLER GROUP, LLC
  78. Install the breather tube (1) to the resonator (2).
  79. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to STANDARD PROCEDURE  .
  80. Fill the cooling system. Refer to STANDARD PROCEDURE .
  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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