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Section 8 (3.6L Engine (Service Information)): Installation: Installation

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

Fig 1: Upper Intake Manifold & Bolts
GC0144183Courtesy of CHRYSLER GROUP, LLC
NOTE:

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

  1. If required, remove the upper intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL .
    Fig 2: Driver Side Engine Lifting Bracket & Bolts
    GC0144309Courtesy of CHRYSLER GROUP, LLC
  2. 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 3: Passenger Side Engine Lifting Bracket & Bolts
    GC0144310Courtesy of CHRYSLER GROUP, LLC
  3. 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.).
    Fig 4: Lifting Sling, Engine Lifting Brackets & Engine Hoist
    GC0144311Courtesy of CHRYSLER GROUP, LLC
  4. 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).
    Fig 5: Transaxle Upper Bellhousing-To-Block Bolts
    GC0122494Courtesy of CHRYSLER GROUP, LLC
  5. Install the transaxle (2) to the engine (1) if required. Secure with six transaxle upper bellhousing-to-block bolts (3) tightened to 70 N.m (52 ft. lbs.).
    Fig 6: Adapter, Engine Support Cradle, Power Train Dolly & Safety Straps
    GC0147013Courtesy of CHRYSLER GROUP, LLC
  6. Position the engine/transaxle assembly on the Power Train Dolly (special tool #6135, Dolly, Power Train) (3) and Engine Support Cradle (special tool #6710A, Cradle, Engine Support) (2).
  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 Adapter (special tool #6848-3, 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/transaxle assembly to the dolly/cradle with safety straps (4). Remove the engine lifting brackets.
  8. If required, install the following components for installation on the replacement engine:
    • Accessory drive belt tensioner.
    • Upper intake manifold support bracket.
    • Block heater (if equipped).
    Fig 7: Upper Engine Mount Bracket, Right Engine Mount Isolator, Ground Strap & Fasteners
    GC0147071Courtesy of CHRYSLER GROUP, LLC
  9. Position the engine/transaxle assembly under the vehicle. Slowly lower the vehicle in short length spans. Inspect at each interval for potential engine or transaxle contact to vehicle components. Move the cradle/dolly fixture as necessary to allow for clearance.
  10. Install three bolts (1) to the RH engine mount bracket (2) and tighten bolts (1) to 55 N.m (41 ft. lbs.).
    Fig 8: LH Engine (Transmission) Mount Bracket & Bolts
    GC0147014Courtesy of CHRYSLER GROUP, LLC
  11. Install two bolts (1) to the LH engine (transmission) mount bracket (2).
  12. Position the main wire harness onto the engine.
    Fig 9: Output Shaft Speed Sensors Connectors, Bracket, Gearshift Cable & Retainers
    GC0147037Courtesy of CHRYSLER GROUP, LLC
  13. Engage the wire harness retainer (1) to the gearshift cable bracket (4).
  14. Connect two output shaft speed sensors connectors (2 and 3).
  15. Connect the gearshift cable (5) from the bracket (4).
    Fig 10: Identifying Shift Cable & Manual Valve Lever
    GC0121541Courtesy of CHRYSLER GROUP, LLC
  16. Connect the gearshift cable (1) from transaxle manual valve lever (2).
    Fig 11: Transmission Input Shaft Speed Sensor Connector & Oil Cooler Lines
    GC0147036Courtesy of CHRYSLER GROUP, LLC
  17. Connect the oil cooler lines (2) to transaxle.
  18. Connect the transmission input shaft speed sensor connector (1).
    Fig 12: Transmission Solenoid Harness Connector & Retainer
    GC0147035Courtesy of CHRYSLER GROUP, LLC
  19. Connect transmission solenoid harness connector (2).
    Fig 13: Torque Converter Bolts
    GC0121567Courtesy of CHRYSLER GROUP, LLC
  20. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
  21. If required, install the four transaxle-to-engine lower bolts (2) and tighten to 70 N.m 52 ft. lbs.).
  22. If required, install the torque converter-to-driveplate bolts (1) and tighten to 88 N.m (65 ft. lbs.).
    Fig 14: Torque Converter Housing Dust Cover & Rubber Plugs
    GC0147034Courtesy of CHRYSLER GROUP, LLC
  23. If required, install the transaxle torque converter housing dust cover (1) and rubber plugs (2).
    Fig 15: Rear Engine Mount Bracket & Bolts
    GC0147033Courtesy of CHRYSLER GROUP, LLC
  24. On FWD vehicles, Install the rear engine mount bracket (1) with four bolts (2) tightened to 110 N.m (81 ft. lbs.) and one bolt (3) tightened to 61 N.m (45 ft. lbs.).
    Fig 16: Heater Core Supply Tube & Bolts
    GC0148113Courtesy of CHRYSLER GROUP, LLC
  25. Lower the vehicle.
  26. If required, install the heater core supply tube (1) with two bolts (2) and tighten to 12 N.m (106 in. lbs.).
    Fig 17: Left Intake Manifold Support Brackets & Retaining Bolts
    GC0144406Courtesy of CHRYSLER GROUP, LLC
  27. Install the LH upper intake manifold support brackets (1). Loosely install the studbolts (2).
    Fig 18: Main Wire Harness Retainers
    GC0147041Courtesy of CHRYSLER GROUP, LLC
  28. Engage three main wire harness retainers (1) to the right cylinder head cover.
    Fig 19: Oil Pump Solenoid Electrical Connector & Wire Harness Retainer
    GC0147028Courtesy of CHRYSLER GROUP, LLC
  29. Connect the oil pump solenoid electrical connector (2).
  30. Engage the wire harness retainer (1) to the engine block.
    Fig 20: Power Steering Pump Bracket Bolts & Retainers
    GC0147040Courtesy of CHRYSLER GROUP, LLC
  31. Install the power steering pump and bracket as an assembly with three bolts (1) and tighten to 25 N.m (18 ft. lbs.).
  32. Engage the wire harness retainer (2) to the power steering pump.
    Fig 21: Power Steering Pump Heat Shield & Bolts
    GC0147039Courtesy of CHRYSLER GROUP, LLC
  33. Install the power steering pump heat shield (1) Tighten bolts (2) to 25 N.m (18 ft. lbs.).
    Fig 22: Crankshaft Position (CKP) Sensor Electrical Connector, Downstream Oxygen Sensor Connector & Wire Harness Retainers
    GC0147030Courtesy of CHRYSLER GROUP, LLC
  34. Connect the power cord to the engine block heater (if equipped).
  35. On FWD vehicles, engage the downstream oxygen sensor connector (4) to the engine mount.
  36. Engage one wire harness retainer (2) to the engine block and one wire harness retainer (1) to the transmission mounting stud.
  37. Connect the Crankshaft Position (CKP) sensor electrical connector (3).
    Fig 23: Crankshaft Position (CKP) Sensor Heat Shield
    GC0147031Courtesy of CHRYSLER GROUP, LLC
  38. Position the heat shield (1) over the Crankshaft Position (CKP) sensor.
    Fig 24: Rear Engine Mount Heat Shield & Bolts
    GC0147032Courtesy of CHRYSLER GROUP, LLC
  39. On FWD vehicles, install the rear engine mount heat shield (2). Tighten bolts (1) to 14 N.m (124 in. lbs.).
    Fig 25: A/C Compressor & Bolts
    GC0147045Courtesy of CHRYSLER GROUP, LLC
  40. Install the A/C compressor (2). Refer to COMPRESSOR, A/C, INSTALLATION .
    Fig 26: Lower Radiator Hose
    GC0145659Courtesy of CHRYSLER GROUP, LLC
  41. Install the lower radiator hose (1).
    Fig 27: Starter Assembly
    GC0147029Courtesy of CHRYSLER GROUP, LLC
  42. Install the starter. Refer to STARTER, INSTALLATION .
    Fig 28: Front Engine Mount Bracket & Bolts
    GC0147038Courtesy of CHRYSLER GROUP, LLC
  43. Install the front engine mount bracket (1). Tighten bolts (2) to 55 N.m (41 ft. lbs.).
    Fig 29: Removing/Installing Power Transfer Unit
    GC0128951Courtesy of CHRYSLER GROUP, LLC
  44. If equipped with AWD, install the PTU (1). Refer to INSTALLATION .
    Fig 30: Rear Engine Mount Isolator, Bracket & Bolts
    GC0148112Courtesy of CHRYSLER GROUP, LLC
  45. If equipped with AWD, install the rear engine mount bracket and isolator assembly (1 and 3). Refer to INSULATOR, ENGINE MOUNT, REAR, INSTALLATION  .
    Fig 31: Aft Crossmember, Crossunder Pipe & Catalytic Converters
    GC0147025Courtesy of CHRYSLER GROUP, LLC
  46. Install both catalytic converters (3) and connect the oxygen sensor connectors to the main wire harness. Refer to CONVERTER, CATALYTIC, INSTALLATION .
  47. Install the crossunder pipe (2). Refer to PIPE, EXHAUST CROSSUNDER, INSTALLATION .
  48. Install the front fore and aft crossmember (1). Refer to CROSSMEMBER, FRONT FORE AND AFT, INSTALLATION .
    Fig 32: Hub Nut & Axle Half Shaft
    GC0128730Courtesy of CHRYSLER GROUP, LLC
  49. Install the intermediate shaft and both axle shafts (2). Refer to INSTALLATION .
    Fig 33: Right Lower Splash Shield
    GC0121547Courtesy of CHRYSLER GROUP, LLC
  50. Install the right lower splash shield (2).
    Fig 34: Left Lower Splash Shield
    GC0128722Courtesy of CHRYSLER GROUP, LLC
  51. Install the left lower splash shield (2).
    Fig 35: Identifying Tire And Wheel Assembly
    GC0124371Courtesy of CHRYSLER GROUP, LLC
  52. Install both front tire and wheel assemblies (1). Refer to INSTALLATION .
    Fig 36: Belly Pan
    GC0121546Courtesy of CHRYSLER GROUP, LLC
  53. Install the belly pan, if equipped.
    Fig 37: Camshaft Position (CMP) Sensor Connector & Harness Retainers
    GC0147024Courtesy of CHRYSLER GROUP, LLC
  54. Lower the vehicle.
  55. Engage the wire harness retainer (2) to the upper intake manifold support bracket mounting stud.
  56. Engage the wire harness retainer (3) to the intake manifold support bracket.
  57. Connect the electrical connector (1) to the right Camshaft Position (CMP) sensor.
    Fig 38: Wire Harness Retainers & Variable Valve Timing Solenoid Connectors
    GC0147023Courtesy of CHRYSLER GROUP, LLC
  58. Engage two wire harness retainers (1) to the right cylinder head cover.
  59. Connect the electrical connectors (2) to the variable valve timing solenoids on the right cylinder head.
    Fig 39: Engine Injection/Ignition Harness & Engine Oil Pressure/Temperature Harness
    GC0144404Courtesy of CHRYSLER GROUP, LLC
  60. Connect the main harness to the engine oil pressure/temperature harness (2) at the rear of the left cylinder head.
  61. Connect the main harness to the engine injection/ignition harness (1) at the rear of the left cylinder head.
    Fig 40: Engine Coolant Temperature (ECT) Sensor Connector, Camshaft Position (CMP) Sensor & Harness Retainers
    GC0147022Courtesy of CHRYSLER GROUP, LLC
  62. Engage the main wire harness retainer (1) to the rear of the lower intake manifold.
  63. Engage one main wire harness retainer (2) to the cylinder head cover and one main wire harness retainer (4) to the cylinder head cover mounting stud.
  64. Connect the left Camshaft Position (CMP) sensor (5).
  65. Connect the Engine Coolant Temperature (ECT) sensor connector (3).
    Fig 41: Left Upstream Oxygen Sensor Connector, Upper Wire Harness Retainers & Lower Wire Harness Retainers
    GC0147020Courtesy of CHRYSLER GROUP, LLC
  66. Engage two lower wire harness retainers (3) to the intake manifold support brackets.
  67. Engage two upper wire harness retainers (2) to the intake manifold support brackets.
  68. Connect the left upstream oxygen sensor connector (1) to the main wire harness.
    Fig 42: Wire Harness Retainers & Variable Valve Timing Solenoid Connectors
    GC0147021Courtesy of CHRYSLER GROUP, LLC
  69. Engage three wire harness retainers (1) to the left cylinder head cover.
  70. Connect the electrical connectors (2) to the variable valve timing solenoids on the left cylinder head cover.
    Fig 43: Generator Fasteners & Generator
    GC0147017Courtesy of CHRYSLER GROUP, LLC
  71. Install the generator (2). Refer to GENERATOR, INSTALLATION .
    Fig 44: Belt Tensioner, Accessory Drive Belt & Belt Routing
    GC0147003Courtesy of CHRYSLER GROUP, LLC
  72. Install the accessory drive belt (7). Refer to BELT, SERPENTINE, INSTALLATION .
    Fig 45: Windshield Washer Reservoir, Core Shroud, Radiator Fan & Mounting Bolts
    GC0147050Courtesy of CHRYSLER GROUP, LLC
  73. Install the cooling fan module (3). Refer to FAN, COOLING, INSTALLATION .
    Fig 46: Upper Radiator Hose
    GC0147058Courtesy of CHRYSLER GROUP, LLC
  74. Install the upper radiator hose (1).
    Fig 47: Upper Intake Manifold & Bolts
    GC0144183Courtesy of CHRYSLER GROUP, LLC
  75. Install the upper intake manifold (2). Refer to MANIFOLD, INTAKE, INSTALLATION .
    Fig 48: Heater Core Return Tube, Nut & Bolt
    GC0147057Courtesy of CHRYSLER GROUP, LLC
  76. Install the heater core return tube (1) with the nut (2) and bolt (3).
    Fig 49: Fuel Line, Heater Core Supply Hose & Return Hose
    GC0148114Courtesy of CHRYSLER GROUP, LLC
  77. Connect the heater core supply hose (2).
  78. Connect the heater core return hose (3).
  79. Connect the fuel line (1) to the fuel rail inlet. Refer to FITTING, QUICK CONNECT .
    Fig 50: Coolant Recovery Container, Return Hose, Lower Supply Hose & Mount Bolts
    GC0147049Courtesy of CHRYSLER GROUP, LLC
  80. Install the coolant recovery bottle (1). Refer to BOTTLE, COOLANT RECOVERY, INSTALLATION .
    Fig 51: Electric Vacuum Pump, Connector & Two Bolts
    GC0147016Courtesy of CHRYSLER GROUP, LLC
  81. Install the electric vacuum pump and mounting bracket (1). Refer to PUMP, ELECTRIC VACUUM, INSTALLATION .
    Fig 52: Resonator, Electrical Connector, Push Pin & Clamp
    GC0147056Courtesy of CHRYSLER GROUP, LLC
  82. Install the resonator (1). Refer to RESONATOR, AIR CLEANER, INSTALLATION .
    Fig 53: Fresh Air Makeup Hose, Air Cleaner Body, Push Pin, Two Bolts & Clamp
    GC0147055Courtesy of CHRYSLER GROUP, LLC
  83. Install the air cleaner body (1). Refer to BODY, AIR CLEANER, INSTALLATION .
    Fig 54: Engine Cover
    GC0147054Courtesy of CHRYSLER GROUP, LLC
  84. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to OIL - STANDARD PROCEDURE  .
  85. Evacuate and recharge Air Conditioning system. Refer to PLUMBING, FRONT, STANDARD PROCEDURE .
  86. Fill the cooling system. Refer to STANDARD PROCEDURE .
  87. Install the engine cover (1).
  88. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
  89. 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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