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Section 5 (6.4L Engine (Service Information)): Installation: Installation

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.

NOTE:

Do not use air tools to install Engine Lift Fixture and Adapter (special tool #8984B, Fixture, Engine Lifting) (2, 3).

  1. Install the engine lift fixture (2) (special tool #8984B, Fixture, Engine Lifting) and adapter (special tool #8984-UPD, Adapter, Engine Lift) (4).
    Fig 1: Engine Lift Fixture & Adapter
    GC0080289Courtesy of CHRYSLER GROUP, LLC
  2. Using a suitable engine hoist, lower the engine into the engine compartment.
  3. Automatic transmission equipped vehicles, align the engine with the transmission.
  4. Install two transmission bell housing to engine block bolts finger tight.
  5. Lower the engine assembly until the engine mounts rest in the engine cradle crossmember.
    Fig 2: 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.

  6. Align the engine mounts, install both left/right engine mount to frame retaining bolts (2) and tighten to 68 N.m (50 ft. lbs.).
  7. Position both left and right engine mount heat shields (4), install the retaining nuts (3) and tighten to 27 N.m (20 ft. lbs.).
  8. Remove the engine hoist and the jack supporting the transmission.
  9. Raise and support the vehicle.
    Fig 3: Remove/Install Transmission To Oil Pan Bolts
    GC0080287Courtesy of CHRYSLER GROUP, LLC
  10. Automatic transmission equipped vehicles, install the oil pan to transmission bolts (1) and tighten to 54 N.m (40 ft. lbs.).
    Fig 4: Remove/Install Transmission To Engine Bolts
    GC0080288Courtesy of CHRYSLER GROUP, LLC
  11. Install the remaining transmission bell housing to engine block bolts (2) and tighten to 68 N.m (50 ft. lbs.).
    Fig 5: Torque Converter Bolts
    GC0080286Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    It is essential that the correct length bolts are used to attach the converter to the flexplate. Bolts that are too long will damage the clutch surface inside the torque converter.

  12. Rotate the crankshaft in clockwise direction and install all torque converter to flexplate bolts (1) finger tight.
  13. Verify that the torque converter is pulled flush to the flexplate and tighten bolts to 88 N.m (65 ft. lbs.).
    Fig 6: Removing Torque Converter Access Cover
    GC0080285Courtesy of CHRYSLER GROUP, LLC
  14. Install the inspection cover (1) and tighten the retaining bolt (2) to 11 N.m (8 ft. lbs.).
    Fig 7: 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.

  15. Connect the CKP sensor electrical connector (1).
    Fig 8: Knock Sensor, Electrical Connector & Bolt
    GC0144624Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Left side shown in illustration, right side similar.

  16. Connect the right and left knock sensor (1) electrical connectors (5).
  17. Install the heat shield onto the right side knock sensor (shield snaps on/off sensor).
  18. Connect the transmission oil cooler lines to their retainers at the oil pan.
    Fig 9: Removing/Installing Starter
    GC0080284Courtesy of CHRYSLER GROUP, LLC
  19. Position the starter motor (1) into the transmission.
  20. Install the three starter motor retaining bolts (2) and tighten to 54 N.m (40 ft. lbs.).
  21. Connect the solenoid wire to the starter motor (snaps in place).
  22. Position the battery cable to the solenoid stud, install the battery cable eyelet nut and tighten to 11 N.m (8 ft. lbs.).
  23. Position the starter heat shield (4) and install the retaining nuts (3).
    Fig 10: Oxygen Sensor, Oxygen Sensor Connector, Ball Flange Nut & LH Catalytic Converter
    GC0080046Courtesy of CHRYSLER GROUP, LLC
  24. Position the catalytic converters (4) onto the exhaust manifold flanges, install the flange nuts (3) and tighten to 41 N.m (30 ft. lbs.).
  25. Connect the oxygen sensor electrical connectors (2).
  26. Position the generator support bracket (3) to the engine mount, install the retaining nut (1) finger tight.
  27. Position the generator support bracket (3) to the generator, install the retaining bolt (2) and tighten to 65 N.m (48 ft. lbs.).
  28. Tighten the generator support bracket (3) to engine mount retaining nut (1) to 28 N.m (21 ft. lbs.).
    Fig 11: Removing/Installing A/C Compressor
    GC0095564Courtesy of CHRYSLER GROUP, LLC
  29. Install the A/C compressor (3). Refer to COMPRESSOR, A/C, REMOVAL .
    Fig 12: Lower Radiator Hose
    GC0095212Courtesy of CHRYSLER GROUP, LLC
    1 - LOWER RADIATOR HOSE
    2 - RADIATOR FAN ASSEMBLY
  30. Install the lower radiator hose (1).
  31. Lower the vehicle.
    Fig 13: Engine Lift Fixture & Adapter
    GC0080289Courtesy of CHRYSLER GROUP, LLC
  32. Remove the engine lift fixture (special tool #8984B, Fixture, Engine Lifting) (2) and adapter (special tool #8984-UPD, Adapter, Engine Lift) (4).
  33. Position the left and right side wiring harness.
    Fig 14: Oil Control Valve, Electrical Connector & Retaining Bolt
    GC0144407Courtesy of CHRYSLER GROUP, LLC
  34. Lubricate the oil control valve (OCV) rubber O-ring seal with clean engine oil.
  35. Install the OCV (3) and rotate into position.
  36. Install the OCV retaining bolt (2) and tighten to 11 N.m (8 ft. lbs.).
  37. Connect the OCV electrical connector (1).
    Fig 15: Coolant Temperature (ECT) Sensor Electrical Connector, Heater Tube & Retaining Bolt
    GC0144611Courtesy of CHRYSLER GROUP, LLC
  38. Position the heater core tube (3) into the water pump.
  39. Install the heater core tube retaining bolt (1) and tighten to 11 N.m (8 ft. lbs.).
  40. Connect the electrical connector to the coolant temperature (ECT) sensor (2).
    Fig 16: Camshaft Position Sensor Electrical Connector & Bolt
    GC0148461Courtesy of CHRYSLER GROUP, LLC
  41. Connect the camshaft position sensor electrical connector (1).
    Fig 17: Heater Hose Supply
    GC0095566Courtesy of CHRYSLER GROUP, LLC
  42. Connect the heater hoses (1, 2).
  43. Connect the ground wires to the rear of each cylinder head.
    Fig 18: Ignition Capacitor, Electrical Connector & Intake Manifold
    GC0080072Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The ignition capacitor (2) is attached to the rear of the left cylinder head.

  44. Connect the ignition capacitor (2) electrical connector (1).
    Fig 19: Ignition Coil Mounting Bolts
    GC0080075Courtesy of CHRYSLER GROUP, LLC
  45. Position the ignition coil electrical harness and connect all ignition coil electrical connectors (1).
    Fig 20: Intake Manifold Removal/Tightening Sequence
    GC0148454Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Install the intake manifold and throttle body as an assembly.

  46. Install the intake manifold. Refer to MANIFOLD, INTAKE, INSTALLATION .
    Fig 21: Power Steering Reservoir, Pump, Pulley & Bolts
    GC0148443Courtesy of CHRYSLER GROUP, LLC
  47. Position the power steering pump (4).
  48. Install the three power steering pump (4) mounting bolts (2) through the access holes in the pulley and tighten the bolts to 28 N.m (21 ft. lbs.).
    Fig 22: Oil Pressure Sensor Electrical Connector
    GC0095586Courtesy of CHRYSLER GROUP, LLC
  49. Connect the oil pressure sensor electrical connector (1).
  50. Connect the oil temperature sensor electrical connector.
    Fig 23: Generator & Mounting Bolts
    GC0081823Courtesy of CHRYSLER GROUP, LLC
  51. Tighten two generator mounting bolts (1) to 65 N.m (48 ft. lbs.).
  52. Snap the field wire connector into the rear of the generator.
  53. Position the generator B+ terminal eyelet to the generator output stud, install the retaining nut and tighten to 13 N.m (10 ft. lbs.).
  54. Snap the plastic insulator cap onto the B+ output terminal.
    Fig 24: Coolant Recovery Bottle, Radiator Neck, Overflow Tube & Fasteners
    GC0145991Courtesy of CHRYSLER GROUP, LLC
  55. Position the coolant bottle (1) and install the coolant bottle retaining bolts (4). Tighten to 10 N.m (89 in. lbs.).
  56. Position the wire harness and secure to the right hand inner fender panel.
    Fig 25: Drive Belt Tensioner And Drive Belt
    GC0144483Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

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

  57. Rotate the accessory drive belt tensioner (7) clockwise until it contacts the stop and install the accessory drive belt (4) onto the pulleys, then slowly release the tensioner.
    Fig 26: Cooling Fan Module Components
    GC0144321Courtesy of CHRYSLER GROUP, LLC
  58. Install the cooling fan. Refer to FAN, COOLING, INSTALLATION .
    Fig 27: Upper Radiator Hose, Clamp, Oil Cooler Return Line Hose & Clamp
    GC0148460Courtesy of CHRYSLER GROUP, LLC
  59. Position the oil cooler hose (4) and Install oil cooler hose clamp (3).
  60. Position the upper radiator hose (2) and Install the upper radiator hose clamp (1).
    Fig 28: Removing/Installing Cowl Panel
    GC0080264Courtesy of CHRYSLER GROUP, LLC
  61. Install the strut tower support (6) and tighten bolts to 38 N.m (28 ft. lbs.).
  62. Install the cowl panel cover (1). Refer to COVER, COWL PANEL, INSTALLATION .
  63. Fill the crankcase with the specified type and amount of engine oil. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
  64. Fill the cooling system with the specified type and amount of engine coolant. Refer to STANDARD PROCEDURE .
    Fig 29: Engine Covers
    GC0148445Courtesy of CHRYSLER GROUP, LLC
  65. Install the engine covers (1) onto the ball studs.
    Fig 30: Intake Air Temperature (IAT) Sensor, Air Cleaner Housing & Duct
    GC0152258Courtesy of CHRYSLER GROUP, LLC
  66. Install the air cleaner housing assembly (1). Refer to BODY, AIR CLEANER, INSTALLATION .
  67. Raise and support the vehicle.
    Fig 31: Crossmember, Crossmember Bolts & Transmission Mount Bolts
    GC0146313Courtesy of CHRYSLER GROUP, LLC
  68. Support the transmission with a suitable jack.
  69. Remove the transmission crossmember assembly.
    Fig 32: Propeller Shaft & Transfer Case
    GC0138688Courtesy of CHRYSLER GROUP, LLC
  70. Install the front drive shaft. Refer to SHAFT, DRIVE, FRONT, INSTALLATION .
  71. Install the crossmember. Refer to CROSSMEMBER, TRANSMISSION, INSTALLATION .
    Fig 33: Transmission Skid Plate & Fasteners
    GC0145980Courtesy of CHRYSLER GROUP, LLC
  72. If equipped, Install the transmission skid plate. Refer to PLATE, SKID, TRANSMISSION, INSTALLATION .
  73. Lower the vehicle.
    Fig 34: Negative Battery Cable
    GC0139402Courtesy of CHRYSLER GROUP, LLC
  74. Connect the negative battery cable (3).
  75. Top the coolant off. Refer to STANDARD PROCEDURE .
  76. Perform the Refrigerant System Charge procedure. Refer to PLUMBING, STANDARD PROCEDURE .
  77. Install the engine covers.
  78. Start the engine and inspect for leaks.
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