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Home › Dodge and Ram › 2021 › ProMaster 2500 › Repair and Diagnosis › Engine Mechanical › Mechanical › 3.6L Engine (Service Information) › Installation

3.6L Engine (Service Information): 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.

NOTE:

If installing a replacement engine, transfer all the necessary components to the replacement engine.

  1. If required, remove the upper intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL .
    GC0144309Courtesy of CHRYSLER GROUP, LLC
  2. Install the Left 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.).
    GC0144310Courtesy of CHRYSLER GROUP, LLC
  3. Install the Right 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.).
    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).
    GC0122494Courtesy of CHRYSLER GROUP, LLC
  5. If required, install the transaxle (2) to the engine (1). Secure with six transaxle upper bellhousing-to-block bolts (3) tightened to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    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.
    GC0160677Courtesy of CHRYSLER GROUP, LLC
  8. 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.
  9. Install three bolts (1) to the RH engine mount bracket (2) and tighten bolts (1) to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0160720Courtesy of CHRYSLER GROUP, LLC
  10. Install the washer (2) and the nut (1) to the LH engine (transmission) mount (3). Tighten to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .

    If the mounting bracket was removed from the transmission, NEW  fasteners MUST  be used during installation. Refer to INSULATOR, ENGINE MOUNT, REAR, INSTALLATION .

    GC0147037Courtesy of CHRYSLER GROUP, LLC
  11. Install the wire harness retainer (1) to the gearshift cable bracket (4).
  12. Connect two output shaft speed sensors connectors (2 and 3).
  13. Connect the gearshift cable (5) to the bracket (4).
    GC0121541Courtesy of CHRYSLER GROUP, LLC
  14. Connect the gearshift cable (1) to the transaxle manual valve lever (2).
    GC0147036Courtesy of CHRYSLER GROUP, LLC
  15. Connect the transmission input shaft speed sensor connector (1).
    GC0147035Courtesy of CHRYSLER GROUP, LLC
  16. Install the wire harness retainer (1) to the valve body pan.
  17. Connect transmission solenoid harness connector (2).
  18. Install the chassis ground at the rear of the transaxle.
    GC0160540Courtesy of CHRYSLER GROUP, LLC
  19. If required, install the five transaxle-to-engine lower bolts (2) and tighten to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
  20. If required, install the torque converter-to-driveplate bolts (1) and tighten to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0147034Courtesy of CHRYSLER GROUP, LLC
  21. If required, install the transaxle torque converter housing dust cover (1) and rubber plugs (2).
    GC0160218Courtesy of CHRYSLER GROUP, LLC
  22. Position the rear side lower transmission strut (2) to the crossmember.
  23. Install the rear through bolt (1). Tighten the bolt to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
  24. Install the strut to pivot through bolt (3). Tighten the bolt to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0160197Courtesy of CHRYSLER GROUP, LLC
  25. Install the transmission cooler lines (2, 4) to the transmission cooler. Tighten the bolt (3) to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0147040Courtesy of CHRYSLER GROUP, LLC
  26. Install the power steering pump and bracket as an assembly with three bolts (1) and tighten to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
  27. Install the wire harness retainers (2) to the power steering pump/bracket.
  28. Connect the power cord to the engine block heater (if equipped).
  29. Install the A/C compressor. Refer to COMPRESSOR, A/C, INSTALLATION .
    GC0145659Courtesy of CHRYSLER GROUP, LLC
  30. Install the lower radiator hose (1).
  31. Install the bypass hose to the water pump.
  32. Install the starter and secure the starter/battery wire harness. Refer to STARTER, INSTALLATION .
  33. Connect the wire harness connections at the Powertrain Control Module (PCM) and secure the engine wire harness to body connections. Refer to MODULE, POWERTRAIN CONTROL (PCM), REMOVAL .
  34. Secure the Power distribution Center (PDC) wire harness connections. Refer to CENTER, POWER DISTRIBUTION (PDC), INSTALLATION .
  35. Secure the engine harness to body ground connections.
  36. Install both catalytic converters and connect the oxygen sensor connectors to the main wire harness. Refer to CONVERTER, CATALYTIC, INSTALLATION .
  37. Install the crossunder pipe. Refer to PIPE, EXHAUST CROSSUNDER, INSTALLATION .
  38. Install the axleshafts and intermediate shaft. Refer to INSTALLATION .
  39. Install the wheel housing splash shields. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, INSTALLATION .
  40. If equipped, install the belly pan. Refer to BELLY PAN, INSTALLATION .
  41. Install the generator wire harness and secure the connections. Refer to GENERATOR, INSTALLATION .
  42. Install the accessory drive belt. Refer to BELT, SERPENTINE, INSTALLATION .
    GC0147395Courtesy of CHRYSLER GROUP, LLC
  43. Connect the fuel line (1) to the fuel rail inlet. Refer to FITTING, QUICK CONNECT, STANDARD PROCEDURE .
  44. Install the fuel and purge line retainer.
  45. Install the upper intake manifold. Refer to MANIFOLD, INTAKE, INSTALLATION .
    GC0157476Courtesy of CHRYSLER GROUP, LLC
  46. Connect the heater core hoses.
  47. Install the upper radiator hose (2) and install the hose retainer (1) to the intake manifold.
    GC0160179Courtesy of CHRYSLER GROUP, LLC
  48. Connect the brake vacuum hose.
  49. Install the vapor hose (3) to the upper intake manifold.
  50. Install the vapor hose (1) to the purge solenoid.
  51. Install the pressurized coolant bottle. Refer to BOTTLE, PRESSURIZED COOLANT, INSTALLATION .
  52. Install the air cleaner resonator and hose assembly. Refer to RESONATOR, AIR CLEANER, INSTALLATION .
  53. Fill engine crankcase with proper oil to correct level.
  54. Evacuate and recharge A/C system. Refer to PLUMBING, STANDARD PROCEDURE .
  55. Fill cooling system. Refer to STANDARD PROCEDURE .
  56. Install the engine cover.
    GC0160639Courtesy of CHRYSLER GROUP, LLC
  57. Connect the negative battery cable and tighten the clamp (1).
  58. Install the battery access cover.
  59. 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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