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Home >> Dodge and Ram >> 2023 >> ProMaster 2500 >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> 3.6L Engine (Service Information) (1 Of 2) >> Installation

3.6L Engine (Service Information) (1 Of 2): Installation

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:

Check condition of the flexplate. Replace the plate if cracked, distorted or damaged. Also be sure transmission dowel pins are seated in engine block and protrude far enough to hold transmission in alignment.

  1. If installing a replacement engine, transfer all the necessary components to the replacement engine.
  2. If required, remove the upper intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL .
    GC0144309Courtesy of CHRYSLER GROUP, LLC
  3. Install the Left Side Engine Lifting Bracket (1) on the LH cylinder head with bolts (2) provided with the Engine Lifting Bracket. Tighten the bolts to the proper specifications. Refer to TORQUE SPECIFICATIONS .

    (Special Tool #2028020090, Lift Bracket, Engine-Left)

    GC0144310Courtesy of CHRYSLER GROUP, LLC
  4. Install the Right Side Engine Lifting Bracket (1) on the RH cylinder head with bolts (2) from the Engine Lifting Bracket. Tighten the bolts to the proper specifications. Refer to TORQUE SPECIFICATIONS .

    (Special Tool #2028010090, Lift Bracket, Engine-Right)

    GC0144311Courtesy of CHRYSLER GROUP, LLC
  5. 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).
    GC0147013Courtesy of CHRYSLER GROUP, LLC
  6. Position the engine/transmission assembly on the Power Train Dolly (3) and Engine Support Cradle (2).

    (Special Tool #6135, Dolly, Power Train) & (Special Tool #6710A, Cradle, Engine Support)

  7. Loosen the cradle engine mounts to allow movement for positioning onto the engine locating holes on the engine block and oil pan rail. Place an Adapter (1) on the front post and align to the oil pan mounting stud. Tighten the post mounts to the cradle frame. Secure the engine/transmission assembly to the dolly/cradle with safety straps (4).

    (Special Tool #6848-3, Adapter)

  8. Remove the left engine lift bracket.
  9. Remove the right engine lift bracket.
  10. Install the heater core supply tube and the fasteners.
  11. Install the upper intake manifold and support brackets. Refer to MANIFOLD, INTAKE, INSTALLATION .
    GC0203959Courtesy of CHRYSLER GROUP, LLC
  12. Install the lower radiator hose (2).
  13. Install the bypass hose (1) to the water pump.
    GC0203990Courtesy of CHRYSLER GROUP, LLC
  14. If required, install the transmission and spacer plate to the engine.
  15. Install the upper bellhousing-to-block bolts (1) and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS .
  16. Install the starter and tighten the bolts to the proper specifications. Refer to TORQUE SPECIFICATIONS .
  17. Install the ground strap bolt and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS .
  18. Attach the battery cable wire harness retainer.
  19. Position a transmission jack under the transmission. Secure the transmission to the transmission jack.
  20. Install the transmission wire harness connectors and retainers to the transmission.
  21. Position the engine/transmission assembly under the vehicle. Slowly lower the vehicle in short length spans. Inspect at each interval for potential engine or transmission contact to vehicle components. Move the cradle/dolly fixture as necessary to allow for clearance.
    GC0203937Courtesy of CHRYSLER GROUP, LLC
  22. Install the right engine mount to bracket bolts (2) and tighten bolts to the proper specifications. Refer to TORQUE SPECIFICATIONS .
    GC0203945Courtesy of CHRYSLER GROUP, LLC
  23. Install the left engine (transmission) mount to bracket bolts (2) and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS .
  24. Raise the vehicle and remove the powertrain dolly and engine support cradle.
  25. Connect the engine harness to body grounds and wire harness retainers.
  26. Install both axle shafts and the intermediate shaft. Refer to INSTALLATION .
  27. Install the rear mount. Refer to INSULATOR, ENGINE MOUNT, REAR, INSTALLATION .
    GC0203865Courtesy of CHRYSLER GROUP, LLC
  28. Install the transmission cooler lines to the transmission cooler (1).
    GC0203927Courtesy of CHRYSLER GROUP, LLC
  29. If required, install the five transmission-to-engine lower bolts (1) and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS .
  30. If required, install the torque converter-to-flexplate bolts (2) and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS .
    GC0147034Courtesy of CHRYSLER GROUP, LLC
  31. Install the transmission torque converter housing dust cover (1).
  32. Install the rubber plugs (2) from the bell housing.
  33. Install the A/C compressor lines and tighten the nut to the proper specifications. Refer to TORQUE SPECIFICATIONS .
  34. Attach the wire harness retainer to the A/C lines.
  35. If equipped, connect the power cord to the engine block heater.
    GC0173589Courtesy of CHRYSLER GROUP, LLC
  36. Connect the EGR temperate sensor wire harness connector (1).
  37. Install the cooling fan. Refer to FAN, COOLING, INSTALLATION .
    GC0203988Courtesy of CHRYSLER GROUP, LLC
  38. Install the rear catalytic converter support bracket bolts (1) and tighten the to the proper specifications. Refer to TORQUE SPECIFICATIONS .
  39. Install both catalytic converters. Refer to CONVERTER, CATALYTIC, INSTALLATION .
    GC0206979Courtesy of CHRYSLER GROUP, LLC
  40. Install the chassis ground cable (1) and securely tighten the bolt (2).
    GC0203938Courtesy of CHRYSLER GROUP, LLC
  41. Install the chassis ground cable (1) and securely tighten the bolt (2) at the rear of the transmission.
    GC0203862Courtesy of CHRYSLER GROUP, LLC
  42. Connect the gearshift cable (2) to the bracket (1).
    GC0204121Courtesy of CHRYSLER GROUP, LLC
  43. Connect the gearshift cable (2) to the transmission manual valve lever (1).
    GC0204005Courtesy of CHRYSLER GROUP, LLC
  44. Connect the coolant hoses (1, 2) to the thermostat housing.
  45. Connect the coolant hose at the EGR cooler.
  46. Install the bracket bolt to the oil level indicator and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS .
    GC0203919Courtesy of CHRYSLER GROUP, LLC
  47. Install the upper coolant tube fasteners (1) and securely tighten.
    GC0203913Courtesy of CHRYSLER GROUP, LLC
  48. Install the upper coolant hose (1) to the radiator.
    GC0204111Courtesy of CHRYSLER GROUP, LLC
  49. Connect the fuel supply line (1) under the brake booster. Refer to QUICK-CONNECT FITTINGS .
    GC0204072Courtesy of CHRYSLER GROUP, LLC
  50. Connect the heater core hoses (1) to the heater core.
  51. Install the cowl drain.
    GC0203854Courtesy of CHRYSLER GROUP, LLC
  52. Connect the vacuum hose (2) near the brake booster and install into the retaining clip (1).
  53. Install the electric vacuum pump. Refer to PUMP, ELECTRIC VACUUM, INSTALLATION .
    GC0160179Courtesy of CHRYSLER GROUP, LLC
  54. Install the fuel and purge line retainer.
  55. Install the vapor hose (3) to the upper intake manifold.
  56. Install the vapor hose (1) to the purge solenoid.
  57. Connect the PDC wire harness.
    GC0206930Courtesy of CHRYSLER GROUP, LLC
  58. Attach the power cable retainer (3) and position the power cable (2).
  59. Install the power cable nut (1) to the PDC and securely tighten.
  60. Install the PDC cover and securely tighten the cover nuts.
  61. Connect the Powertrain Control Module (PCM) wire harness connectors.
    GC0206932Courtesy of CHRYSLER GROUP, LLC
  62. Install the PCM cover (1) and securely tighten the fasteners.
  63. Connect the wire harness connector (2) and attach the wire harness retainer to the PCM cover (1).
  64. Install the pressurized coolant bottle bracket and securely tighten the pressurized coolant bottle bracket bolts.
  65. Install the pressurized coolant bottle. Refer to BOTTLE, PRESSURIZED COOLANT, INSTALLATION .
  66. Install the air cleaner resonator and hose assembly. Refer to RESONATOR, AIR CLEANER, INSTALLATION .
  67. Install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to STANDARD PROCEDURE - ENGINE OIL AND FILTER CHANGE .
  68. Evacuate and recharge A/C system. Refer to REFRIGERANT SYSTEM RECOVERY .
  69. Fill cooling system. Refer to COOLANT SYSTEM AIR EVACUATION .
  70. Install the belly pan and splash shields. Refer to BELLY PAN, INSTALLATION .
  71. Connect the negative battery cable.
  72. Install the battery access cover.
  73. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to COOLANT SYSTEM AIR EVACUATION .
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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