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Section 3 (6.4L Engine (Service Information)): Removal: Removal

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

If the engine encounters a catastrophic failure, the engine oil cooler must be replaced or damage to the new engine and/or components could result.

Fig 1: Cowl Panel, Push-Pins & Fasteners
GC0080264Courtesy of CHRYSLER GROUP, LLC
  1. Remove the hood. Refer to HOOD, REMOVAL .
  2. Remove the cowl panel cover (1). Refer to COVER, COWL PANEL, REMOVAL .
  3. Remove the strut tower support (6).
    Fig 2: Engine Covers
    GC0148445Courtesy of CHRYSLER GROUP, LLC
  4. Lift the engine cover retaining grommets off the ball studs and remove the engine covers (1).
  5. Perform the fuel system pressure release procedure. Refer to FUEL SYSTEM PRESSURE RELEASE .
    Fig 3: Negative Battery Cable
    GC0139402Courtesy of CHRYSLER GROUP, LLC
  6. Disconnect and isolate the negative battery cable (1).
    Fig 4: Intake Manifold Removal/Tightening Sequence
    GC0148454Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Remove the intake manifold and throttle body as an assembly.

  7. Remove the intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL .
    Fig 5: Oil Control Valve, Electrical Connector & Retaining Bolt
    GC0144407Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The engine must be at room temperature before removing the oil control valve.

  8. Disconnect the oil control valve electrical connector (1).
  9. Remove the oil control valve retaining bolt (2).
  10. Rotate the oil control valve (3) to break the seal then pull the oil control valve straight out.
    CAUTION:

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

    Fig 6: Identifying Accessory Drive Belt, Tensioner & Pulleys
    GC0118256Courtesy of CHRYSLER GROUP, LLC
  11. Rotate the accessory drive belt tensioner (8) clockwise until it contacts the stop and remove the accessory drive belt (2), then slowly rotate the tensioner into the freearm position.
    Fig 7: Cooling Fan Module Components
    GC0144321Courtesy of CHRYSLER GROUP, LLC
  12. Remove the cooling fan (1). Refer to FAN, COOLING, REMOVAL .
  13. Raise and support the vehicle.
    Fig 8: Lower Splash Shield & Fasteners
    GC0095584Courtesy of CHRYSLER GROUP, LLC
  14. Remove the belly pan retainers (1) and remove the belly pan.
  15. Drain the cooling system. Refer to STANDARD PROCEDURE .
  16. Drain the engine oil. Refer to Engine/Lubrication/OIL - Standard Procedure .
    Fig 9: Removing/Installing A/C Compressor
    GC0095564Courtesy of CHRYSLER GROUP, LLC
  17. Remove the A/C compressor (3). Refer to COMPRESSOR, A/C, REMOVAL .
    Fig 10: Engine Mount Heat Shield Retaining Nuts, Lower Mount Retaining Bolts & Heat Shields
    GC0144614Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Left side shown in illustration, right side similar.

  18. Remove both left/right engine mount heat shield (4) retaining nuts (3) and remove the heat shields.
  19. Remove both left/right engine mount to frame retaining bolts (2).
  20. Disconnect the transmission oil cooler lines from their retainers at the oil pan.
    Fig 11: Lower Radiator Hose & Radiator Fan Assembly
    GC0095212Courtesy of CHRYSLER GROUP, LLC
    1 - LOWER RADIATOR HOSE
    2 - RADIATOR FAN ASSEMBLY
  21. Remove the lower radiator hose (1).
    Fig 12: Knock Sensor, Electrical Connector & Bolt
    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.

    NOTE:

    Left side shown in illustration, right side similar.

  22. Remove the heat shields from both knock sensors (shield snaps on/off sensor).
  23. Disconnect the knock sensor electrical connectors (3).
    CAUTION:

    When separating the catalytic converters from the manifolds, disconnect the oxygen sensor connectors. Allowing the catalytic converters hanging from the oxygen sensor wires damages the harness and/or sensors.

    Fig 13: Oxygen Sensor, Oxygen Sensor Connector, Ball Flange Nut & LH Catalytic Converter
    GC0080046Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Left side shown in illustration, right side similar.

  24. Disconnect all oxygen sensor electrical connectors (2).
  25. Saturate all exhaust bolts and nuts (3) with Mopar® Rust Penetrant. Allow five minutes for penetration.
  26. Remove the both catalytic converter to manifold flange nuts (3) and separate the catalytic converters (4) from the exhaust manifolds.
    Fig 14: Removing/Installing Starter
    GC0080284Courtesy of CHRYSLER GROUP, LLC
  27. Remove the starter motor (1) heat shield (4).
  28. Disconnect the starter wires, remove the starter motor retaining bolts (2) and remove the starter (1). Refer to STARTER, REMOVAL .
    Fig 15: Crankshaft Position Sensor Electrical Connector
    GC0095565Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

  29. Remove the CKP sensor electrical connector (1).
    Fig 16: Support Bracket, Bolt & Nut
    GC0144621Courtesy of CHRYSLER GROUP, LLC
  30. Remove the generator support bracket to engine mount retaining nut (1).
  31. Remove the generator support bracket retaining bolt (2) and remove the support bracket (3).
  32. Lower the vehicle.
    Fig 17: Generator & Retaining Bolt
    GC0080022Courtesy of CHRYSLER GROUP, LLC
  33. Unsnap the plastic insulator cap from the B+ output terminal.
  34. Remove the B+ terminal mounting nut at the rear of the generator and remove the B+ terminal.
  35. Depress the field wire connector tab at the rear of the generator and disconnect the field wire connector.
  36. Remove the two generator retaining bolts (1) and remove the generator (2).
    Fig 18: Removing/Installing A/C Liquid Line
    GC0081079Courtesy of CHRYSLER GROUP, LLC
  37. Remove the nut (1) from the front section of the A/C liquid line (2) to the rear section of the liquid line (3), separate the lines, remove and discard the dual plane seal.
  38. Install plugs or tape over the opened liquid line fittings.
  39. Remove the front section of the A/C liquid line (2) from the engine compartment.
    Fig 19: Removing/Installing A/C Suction Lines
    GC0081082Courtesy of CHRYSLER GROUP, LLC
  40. Remove the nut (1) from the front section of the A/C suction line (2) to the rear section of the suction line (3), separate the lines, remove and discard the dual plane seal.
  41. Install plugs or tape over the opened suction line fittings.
  42. Remove the front section of the A/C suction line (2) from the engine compartment.
    Fig 20: Oil Pressure Sensor Electrical Connector
    GC0095586Courtesy of CHRYSLER GROUP, LLC
  43. Remove the oil pressure sensor electrical connector (1).
  44. Remove the oil temperature sensor electrical connector.
    Fig 21: Power Steering Reservoir, Pump, Pulley & Bolts
    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.

  45. Remove the three power steering pump (4) mounting bolts (2) through the access holes in the pulley (3) and position the pump aside.
    Fig 22: Upper Radiator Hose, Clamp, Oil Cooler Return Line Hose & Clamp
    GC0148460Courtesy of CHRYSLER GROUP, LLC
  46. Remove the upper radiator hose clamp (1) and remove the upper radiator hose (2).
  47. Remove the oil cooler hose clamp (3) and remove the oil cooler hose (4).
    Fig 23: Coolant Temperature (ECT) Sensor Electrical Connector, Heater Tube & Retaining Bolt
    GC0144611Courtesy of CHRYSLER GROUP, LLC
  48. Remove the heater tube retaining bolt (1).
  49. Remove the coolant temperature sensor electrical connector (2).
  50. Lift the heater tube (3) out of the water pump.
    Fig 24: Camshaft Position Sensor Electrical Connector & Bolt
    GC0148461Courtesy of CHRYSLER GROUP, LLC
  51. Disconnect the camshaft position sensor electrical connector (1).
    Fig 25: Heater Hose Supply
    GC0095566Courtesy of CHRYSLER GROUP, LLC
  52. Remove the heater hoses (1, 2).
    Fig 26: Coolant Recovery Container Pressure Cap, Tube & Screws
    GC0144485Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

  53. Remove the coolant bottle retaining bolts (2) and position the coolant bottle (1) aside.
    Fig 27: Ignition Coil Connector, Ignition Coil & Mounting Bolts
    GC0080075Courtesy of CHRYSLER GROUP, LLC
  54. Remove all ignition coil electrical connectors (1) and position the harness aside.
    Fig 28: TIPM/PDC Mounting Bracket
    GC0081538Courtesy of CHRYSLER GROUP, LLC
  55. Remove the Power Distribution Center (PDC) and mounting bracket.
  56. Unfasten the wire harness mounted on the right hand inner fender panel and position aside.
    Fig 29: Ignition Capacitor, Electrical Connector & Intake Manifold
    GC0080072Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

  57. Remove the ignition capacitor (1) electrical connector (2).
  58. Remove the ground wires from the rear of each cylinder head.
  59. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
    Fig 30: Remove/Install Torque Converter Access Cover
    GC0081819Courtesy of CHRYSLER GROUP, LLC
  60. Remove the transmission inspection cover retaining bolt (2) and remove the inspection cover (1).
    Fig 31: Torque Converter Bolts
    GC0095570Courtesy of CHRYSLER GROUP, LLC
  61. 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).
    Fig 32: Remove/Install Transmission To Oil Pan Bolts
    GC0081820Courtesy of CHRYSLER GROUP, LLC
  62. Remove the oil pan to transmission bolts (1).
    Fig 33: Remove/Install Transmission To Engine Bolts
    GC0081821Courtesy of CHRYSLER GROUP, LLC
  63. Remove the transmission bell housing to engine block bolts (2).
    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.

  64. Lower the vehicle.
    Fig 34: Engine Lift Fixture & Adapter
    GC0081822Courtesy of CHRYSLER GROUP, LLC
  65. Using a suitable jack, support the transmission.
    NOTE:

    Do not use air tools to install engine lift fixture.

  66. Install the (special tool #8984B, Fixture, Engine Lifting) (2) and (special tool #8984-UPD, Adapter, Engine Lift) (4).
  67. Using a suitable engine hoist, separate the engine from the transmission and remove the engine from the engine compartment.
  68. Secure the engine onto a suitable engine stand.
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