LEMON Manuals: Even more car manuals for everyone
Home >> Dodge and Ram >> 2023 >> ProMaster 2500 >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> 3.6L Engine (Service Information) (1 Of 2) >> Removal

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

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 System Pressure Release procedure. Refer to FUEL SYSTEM PRESSURE RELEASE PROCEDURE .
  2. Remove the battery access cover.
  3. Disconnect and isolate the negative battery cable.
  4. Recover the refrigerant from the A/C system. Refer to REFRIGERANT SYSTEM RECOVERY .
  5. Remove the air cleaner resonator and clean air hose assembly. Refer to RESONATOR, AIR CLEANER, REMOVAL .
  6. Remove the belly pan and lower splash shields. Refer to BELLY PAN, REMOVAL .
  7. Drain the cooling system. Refer to DRAINING .
  8. Drain the engine oil. Refer to STANDARD PROCEDURE - ENGINE OIL AND FILTER CHANGE .
  9. Remove the pressurized coolant bottle. Refer to BOTTLE, PRESSURIZED COOLANT, REMOVAL .
    NOTE:

    The wire harness retainer will remain attached to the pressurized coolant bottle bracket.

  10. Remove the pressurized coolant bottle bracket bolts and the pressurized coolant bottle bracket.
    GC0206932Courtesy of CHRYSLER GROUP, LLC
  11. Disconnect the wire harness connector (2) and detach the wire harness retainer from the Powertrain Control Module (PCM) cover (1).
  12. Remove the fasteners and the PCM cover (1).
  13. Disconnect the PCM wire harness connectors and position aside.
  14. Remove the Power Distribution Center (PDC) nuts and the PDC cover.
    GC0206930Courtesy of CHRYSLER GROUP, LLC
  15. Remove the power cable nut (1) from the PDC.
  16. Detach the power cable retainer (3) and position aside the power cable (2).
  17. Disconnect the PDC wire harness and position aside.
    GC0160179Courtesy of CHRYSLER GROUP, LLC
  18. Remove the vapor hose (3) from the intake manifold.
  19. Disconnect the vapor hose (1) from the purge valve.
  20. Remove the fuel and purge line retainer.
  21. Remove the electric vacuum pump and bracket. Refer to PUMP, ELECTRIC VACUUM, REMOVAL .
    GC0203854Courtesy of CHRYSLER GROUP, LLC
  22. Disconnect the vacuum hose (2) near the brake booster and remove from the retaining clips (1).
  23. Remove the cowl drain.
    GC0204072Courtesy of CHRYSLER GROUP, LLC
  24. Disconnect the heater hoses (1) from the heater core.
    GC0204111Courtesy of CHRYSLER GROUP, LLC
  25. Disconnect the fuel line (1) under the brake booster.
    GC0203913Courtesy of CHRYSLER GROUP, LLC
  26. Disconnect the upper coolant hose (1) from the radiator.
    GC0203919Courtesy of CHRYSLER GROUP, LLC
  27. Remove the upper coolant hose fasteners (1).
  28. Remove the bracket bolt from the oil dipstick tube.
  29. Disconnect the coolant hose at the EGR cooler.
    GC0204005Courtesy of CHRYSLER GROUP, LLC
  30. Disconnect the coolant hoses (1, 2) from the thermostat housing and remove the coolant hose assembly.
    GC0204121Courtesy of CHRYSLER GROUP, LLC
  31. Disconnect the gearshift cable (2) from transmission manual valve lever (1).
  32. Detach the transmission shift cable retainer from bracket.
    GC0203862Courtesy of CHRYSLER GROUP, LLC
  33. Disconnect the gearshift cable (2) from the bracket (1) and position gearshift cable aside.
    GC0203938Courtesy of CHRYSLER GROUP, LLC
  34. Remove the bolt (2) and chassis ground cable (1) at the rear of the transmission.
    GC0206979Courtesy of CHRYSLER GROUP, LLC
  35. Remove the chassis ground cable bolt (2) and chassis ground cable (1).
  36. Remove the rear catalytic converter. Refer to CONVERTER, CATALYTIC, REMOVAL .
    GC0203988Courtesy of CHRYSLER GROUP, LLC
  37. Remove the rear catalytic converter bracket bolts (1).
  38. Remove the cooling fan. Refer to FAN, COOLING, REMOVAL .
    GC0173589Courtesy of CHRYSLER GROUP, LLC
  39. Disconnect the EGR temperature sensor wire harness connector (1) and retainer.
  40. If equipped, disconnect and position aside the power cord from the engine block heater.
  41. Detach the wire harness retainer from the A/C lines.
  42. Remove the nut and the A/C lines from the A/C compressor.
    GC0147034Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    If the transmission is to be eventually separated from the engine, removal of the torque converter bolts and lower transmission mounting bolts are best accomplished at this time.

  43. Remove the rubber plugs (2) from the bell housing.
  44. Remove the torque convertor housing dust cover (1).
    GC0203927Courtesy of CHRYSLER GROUP, LLC
  45. If required, remove the torque converter-to-flexplate bolts (2).
  46. If required, remove the five transmission-to-engine lower bolts (1).
    GC0203865Courtesy of CHRYSLER GROUP, LLC
  47. Disconnect the transmission cooler lines from the transmission cooler (1) and position aside.
  48. Remove the rear mount. Refer to INSULATOR, ENGINE MOUNT, REAR, REMOVAL .
  49. Remove both axle shafts and the intermediate shaft. Refer to REMOVAL .
  50. Disconnect the engine harness to body grounds and wire harness retainers and position the harness to be removed with the engine.
    GC0147013Courtesy of CHRYSLER GROUP, LLC
  51. Raise and position vehicle height to allow a Power Train Dolly (3) and an Engine Support Cradle (2) to be installed under the engine/transmission assembly.

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

  52. 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. Lower the vehicle and position cradle until the engine is resting on the posts. 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)

  53. Lower the vehicle so that the weight of the engine and transmission ONLY is on the cradle.
    GC0203945Courtesy of CHRYSLER GROUP, LLC
  54. Remove the left engine (transmission) mount bolts (2).
    GC0203937Courtesy of CHRYSLER GROUP, LLC
  55. Remove the right engine mount bolts (2).
  56. Raise and support the vehicle.
  57. Remove the transmission wire harness connectors and retainers from the transmission.
  58. Position a transmission jack under the transmission. Secure the transmission to the transmission jack.
  59. Release the battery cable wire harness retainer.
  60. Remove the ground strap bolt.
  61. Remove the starter bolts and position aside the starter.
    GC0203990Courtesy of CHRYSLER GROUP, LLC
  62. Remove the remaining transmission upper bellhousing-to-block bolts (1).
  63. Remove the transmission and spacer plate from the engine.
    GC0203959Courtesy of CHRYSLER GROUP, LLC
  64. Remove the lower radiator hose (2).
  65. Remove the bypass hose (1) from the water pump.
  66. Remove the upper intake manifold and support brackets. Refer to MANIFOLD, INTAKE, REMOVAL .
  67. Remove the fasteners and the heater core supply tube.
    GC0144309Courtesy of CHRYSLER GROUP, LLC
  68. 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
  69. 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
  70. Position a load-leveling lifting sling (2), such as OTC® 4305 Engine Load Leveler or commercially available equivalent, between the engine lifting brackets (3) and an engine hoist (1).
  71. Remove the engine from the cradle/dolly fixture.
  72. If required, transfer necessary components for installation onto the replacement engine.
scientia non olet · About LEMON Manuals