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Section 210 (3.6L Engine (Service Information)): Installation: Installation

WARNING: This page is about a different car, the 2012 Dodge Charger. However, it is still accessible from the selected car via links, so may be relevant.
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, transfer the following components onto the replacement engine:
    • Left exhaust down pipe
    • Right exhaust down pipe
    • Left engine mount bracket
    • Left engine mount
    • Right engine mount bracket
    • Right engine mount
    • Accessory drive belt tensioner
    • Upper intake manifold support bracket
    • Block heater (if equipped)
  2. If required, remove the upper intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL .
    Fig 2: Left Intake Manifold Support Brackets & Retaining Bolts
    GC0144406Courtesy of CHRYSLER GROUP, LLC
  3. Remove the left intake manifold support bracket retaining bolts (2) and remove the support brackets (1).
    Fig 3: Driver Side Engine Lifting Bracket & Bolts
    GC0144309Courtesy of CHRYSLER GROUP, LLC
  4. Install the Driver Side Engine Lifting Bracket (special tool #10242-1, Brackets, Engine Lifting, Left Side) (1) on the left cylinder head with bolts (2) provided with the Engine Lifting Bracket and tighten bolts to 21 N.m (15 ft. lbs.).
    Fig 4: Passenger Side Engine Lifting Bracket & Bolts
    GC0144310Courtesy of CHRYSLER GROUP, LLC
  5. Install the Passenger Side Engine Lifting Bracket (special tool #10242-2, Brackets, Engine Lifting, Right Side) (1) on the right cylinder head with bolts (2) provided with the Engine Lifting Bracket and tighten bolts to 21 N.m (15 ft. lbs.).
    Fig 5: Lifting Sling, Engine Lifting Brackets & Engine Hoist
    GC0144311Courtesy of CHRYSLER GROUP, LLC
  6. 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).
  7. Reposition the starter wire harness and the main wire harness to the rear of the engine compartment.
    Fig 6: Engine Mount Heat Shield Retaining Nuts, Lower Mount Retaining Bolts & Heat Shields
    GC0144614Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Left engine mount shown in illustration, right engine mount similar.

  8. Carefully lower the engine into the engine compartment while aligning the two locator dowels into the transmission housing.
  9. Align the engine mounts, install both left and right engine mount lower retaining bolts (2) and tighten to 68 N.m (50 ft. lbs.).
  10. Position both left and right engine mount heat shields (4), install the retaining nuts (3) and tighten to 12 N.m (9 ft. lbs.).
    Fig 7: Electric Vacuum Pump, Bolts & Studs
    GC0144605Courtesy of CHRYSLER GROUP, LLC
  11. Position the electric vacuum pump (3), install the two transmission to engine retaining bolts (2) and tighten to 55 N.m (41 ft. lbs.).
    Fig 8: Electrical Connector, Harness Connector, Hose & Vacuum Pump
    GC0144609Courtesy of CHRYSLER GROUP, LLC
  12. Install the quick connect vacuum hose (2) to the electric vacuum pump (3).
  13. Connect the electrical connector (1) to the electric vacuum pump (3).
  14. Secure the harness retainer (4) to the mounting bracket.
    Fig 9: Left Intake Manifold Support Brackets & Retaining Bolts
    GC0144406Courtesy of CHRYSLER GROUP, LLC
  15. Remove the engine lifting brackets and position the left upper intake manifold support brackets (1) and install the retaining studs (2) finger tight.
    Fig 10: Starter Wire Harness Retainers, Main Wire Harness Retainer & Manifold Support Bracket Retainers
    GC0144415Courtesy of CHRYSLER GROUP, LLC
  16. Route the main wire harness and starter wire harness on the engine.
  17. Secure the two starter wire harness retainers (1) to the upper intake manifold support brackets.
  18. Secure the main wire harness retainer (3) to the left cylinder head cover and two retainers (2) to the upper intake manifold support brackets.
    Fig 11: ECT Sensor Connector, CMP Sensor & Main Wire Harness Retainers
    GC0144416Courtesy of CHRYSLER GROUP, LLC
  19. Connect the Engine Coolant Temperature (ECT) sensor connector (3).
  20. Connect the left Camshaft Position (CMP) sensor (5).
  21. Secure the main wire harness retainer (2) to the cylinder head cover and one main wire harness retainer (4) to the cylinder head cover mounting stud.
  22. Secure the main wire harness retainer (1) to the rear of the lower intake manifold.
    Fig 12: Main Wire Harness Retainers At Right Cylinder Head Cover
    GC0144409Courtesy of CHRYSLER GROUP, LLC
  23. Secure the four main wire harness retainers (1) to the right cylinder head cover.
    Fig 13: Variable Valve Timing Solenoid Connectors & Harness Retainers
    GC0144413Courtesy of CHRYSLER GROUP, LLC
  24. Connect the electrical connectors (2) to the variable valve timing solenoids on the right cylinder head.
  25. Secure the two starter wire harness retainers (1) to the right cylinder head cover.
  26. Secure the starter harness to main harness retainer (3).
    Fig 14: Wire Harness Retainers, Oil Pump Solenoid Electrical Connector & Ground Strap
    GC0144414Courtesy of CHRYSLER GROUP, LLC
  27. Connect the oil pump solenoid electrical connector (2).
  28. Secure the four wire harness retainers (1).
  29. Install the ground strap (3) to the right engine mount bracket.
    Fig 15: Transmission-To-Engine Oil Pan Bolts
    GC0144171Courtesy of CHRYSLER GROUP, LLC
  30. Remove the jack supporting the transmission.
  31. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
  32. Install the four transmission to the engine oil pan retaining bolts (1) and tighten to 55 N.m (41 ft. lbs.).
    Fig 16: Rubber Plugs
    GC0144915Courtesy of CHRYSLER GROUP, LLC
  33. Install the two rubber plugs (1) covering the rear oil seal retainer flange bolts.
    Fig 17: Side Engine-To-Transmission Bolt, Transmission Dust Shield Retaining Bolt & Dust Shield
    GC0144170Courtesy of CHRYSLER GROUP, LLC
  34. Install the side engine to transmission retaining bolt (1) and tighten to 55 N.m (41 ft. lbs.).
  35. Position the torque converter dust shield (3), install the retaining bolt (2) and tighten to 12 N.m (9 ft. lbs.).
    Fig 18: Upper Side Transmission-To-Engine Retaining Bolts
    GC0144667Courtesy of CHRYSLER GROUP, LLC
  36. Install the two upper side transmission to engine retaining bolts (1) and tighten to 55 N.m (41 ft. lbs.).
    Fig 19: Engine Injection/Ignition Harness & Engine Oil Pressure/Temperature Harness
    GC0144404Courtesy of CHRYSLER GROUP, LLC
  37. Connect the main harness to the engine injection/ignition harness (1) at the rear of the left cylinder head.
  38. Connect the main harness to the engine oil pressure/temperature harness (2) at the rear of the left cylinder head.
    Fig 20: Torque Converter Bolt
    GC0144169Courtesy of CHRYSLER GROUP, LLC
  39. Rotate the crankshaft in a clockwise direction and install the six torque converter bolts (1) through the starter mounting hole and tighten to 42 N.m (31 ft. lbs.).
    Fig 21: Bolt & Transmission Cooling Lines
    GC0144918Courtesy of CHRYSLER GROUP, LLC
  40. Install the transmission cooling lines (2) and tighten the bolt (1) to 12 N.m (106 in. lbs.).
    Fig 22: Wire Harness Retainers
    GC0144417Courtesy of CHRYSLER GROUP, LLC
  41. Secure the starter wire harness retainer (2) and the main wire harness retainer (1) to the engine block.
  42. Install the starter. Refer to STARTER, INSTALLATION .
    Fig 23: Main Wire Harness Retainers & CKP Sensor
    GC0144418Courtesy of CHRYSLER GROUP, LLC
  43. Connect the power cord to the engine block heater (if equipped).
  44. Connect the main wire harness to the Crankshaft Position (CKP) sensor (3).
  45. Secure the main wire harness retainer (1) to the engine block and one main wire harness retainer (2) to the right engine mounting bracket.
    Fig 24: CKP Sensor Heat Shield
    GC0144496Courtesy of CHRYSLER GROUP, LLC
  46. Position the heat shield (1) over the crankshaft position (CKP) sensor.
    Fig 25: Removing/Installing Front Axle
    GC0081412Courtesy of CHRYSLER GROUP, LLC
  47. If equipped with AWD, install the front axle assembly (1) with propeller shaft, intermediate shaft, halfshafts, wheels and tires. Refer to INSTALLATION .
  48. If required, fill the front axle with the specified type and amount of gear lubricant.
    Fig 26: Exhaust Down Pipe & Retaining Nuts
    GC0144658Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Left side shown in illustration, right side similar.

  49. Position both left and right exhaust down pipes (1) to the catalytic converters, install the retaining nuts (2) and tighten to 30 N.m (22 ft. lbs.)
    Fig 27: Upstream Oxygen Sensor & Electrical Connector
    GC0144655Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Left side shown in illustration, right side similar.

  50. Connect both left and right upstream oxygen sensor (2) electrical connectors (1) to the main wire harness.
    Fig 28: Lower Splash Shield & Fasteners
    GC0095584Courtesy of CHRYSLER GROUP, LLC
  51. Position the belly pan and install the retainers (1).
  52. Lower the vehicle.
    Fig 29: Upper Intake Manifold Bolt Tightening Sequence
    GC0144185Courtesy of CHRYSLER GROUP, LLC
  53. Install the upper intake manifold and insulator. Refer to MANIFOLD, INTAKE, INSTALLATION .
    Fig 30: Heater Core Inlet Tube, Oil Level Indicator & Bolts
    GC0144913Courtesy of CHRYSLER GROUP, LLC
  54. Install the oil level indicator (2) with bolt (1) tightened to 12 N.m (106 in. lbs.).
  55. Position the heater core inlet tube (4) and install two bolts (3) tightened to 12 N.m (106 in. lbs.).
    Fig 31: A/C Compressor, Nut, Stud & Three Bolts
    GC0144012Courtesy of CHRYSLER GROUP, LLC
  56. Install the A/C compressor (2). Refer to COMPRESSOR, A/C, INSTALLATION .
    Fig 32: Heater Core Return Tube Upper Support Bracket Retaining Nut & Tube
    GC0144665Courtesy of CHRYSLER GROUP, LLC
  57. Position the heater core return tube (1), install the upper support bracket retaining nut (2) and tighten to 12 N.m (9 ft. lbs.).
    Fig 33: Heater Core Return Hose
    GC0144664Courtesy of CHRYSLER GROUP, LLC
  58. Connect the heater core return hose (1).
    Fig 34: Heater Core Return Tube Lower Support Bracket Retaining Nut
    GC0144661Courtesy of CHRYSLER GROUP, LLC
  59. Position the heater core return tube lower support bracket onto the A/C lower retaining stud, install the retaining nut (1) and tighten to 12 N.m (9 ft. lbs.).
    Fig 35: Lower Heater Core Return Hose & Lower Radiator Hose
    GC0144660Courtesy of CHRYSLER GROUP, LLC
  60. Install the lower heater core return hose (1) to the engine coolant pump housing.
  61. Install the lower radiator hose (2) to the engine coolant pump housing.
    Fig 36: Upper Radiator Hose
    GC0144173Courtesy of CHRYSLER GROUP, LLC
  62. Install the upper radiator hose (1) to the engine thermostat housing.
    Fig 37: Variable Valve Timing Solenoid Connectors & Wire Harness Retainers
    GC0144410Courtesy of CHRYSLER GROUP, LLC
  63. Connect the electrical connectors (2) to the left variable valve timing solenoids.
  64. Secure the two starter wire harness retainers (1) to the left cylinder head cover.
    Fig 38: A/C Compressor Electrical Connector & Wire Harness Retainer
    GC0144411Courtesy of CHRYSLER GROUP, LLC
  65. Connect the A/C compressor electrical connector (1) and secure the wire harness retainer (2) to the A/C compressor discharge line.
    Fig 39: Idler Pulley, Tensioner Arm, Belt, Idler, Tensioner & Belt
    GC0144013Courtesy of CHRYSLER GROUP, LLC
  66. Install the generator (1). Refer to GENERATOR, INSTALLATION .
  67. Rotate the accessory drive belt tensioner (7) counterclockwise until it contacts the stop and install the accessory drive belt (3), then slowly rotate the tensioner into position.
    Fig 40: Cooling Fan Module Components
    GC0144321Courtesy of CHRYSLER GROUP, LLC
  68. Install the cooling fan module. Refer to FAN, COOLING, INSTALLATION .
    Fig 41: Fuel Supply Hose At Underbody Fuel Supply Tube
    GC0144399Courtesy of CHRYSLER GROUP, LLC
  69. Connect the fuel supply hose (1) to the underbody fuel tube (2). Refer to FITTING, QUICK CONNECT, STANDARD PROCEDURE .
    Fig 42: Fresh Air Makeup Hose At Rear Of Intake Manifold
    GC0144653Courtesy of CHRYSLER GROUP, LLC
  70. Connect the fresh air makeup hose (2) to the rear of the intake manifold (1).
    Fig 43: PCV Valve, Intake Manifold, Brake Booster Vacuum Hose, MAP Sensor, ETC & CMP Sensor Electrical Connectors
    GC0144654Courtesy of CHRYSLER GROUP, LLC
  71. Connect the electrical connector to the right Camshaft Position Sensor (CMP) (6).
  72. Secure the main wire harness retainer to the right cylinder head cover mounting stud.
  73. Connect the electrical connector to the Electronic Throttle Control (ETC) (5).
  74. Connect the electrical connector to the Manifold Absolute Pressure (MAP) Sensor (4).
  75. Connect the brake booster vacuum hose (3).
  76. Connect the PCV hose to the PCV valve (1) and to the intake manifold (2).
    Fig 44: EVAP Purge Solenoid, Electrical Connector & Vacuum Lines
    GC0144652Courtesy of CHRYSLER GROUP, LLC
  77. Position the EVAP purge solenoid (1) vacuum line (4) and connect the vacuum line to the intake manifold.
  78. Connect the other end of the vacuum line (3) to the EVAP purge solenoid (1).
    Fig 45: Heater Core Purge Hose, Coolant Bottle Retaining Bolts & Coolant Bottle
    GC0144663Courtesy of CHRYSLER GROUP, LLC
  79. Position the coolant bottle (3) into the engine compartment.
  80. Install the coolant bottle retaining bolts (2) and tighten to 12 N.m (9 ft. lbs.).
  81. Connect the heater core purge hose (1) to the coolant bottle.
    Fig 46: Coolant Bottle Return Hose
    GC0144662Courtesy of CHRYSLER GROUP, LLC
  82. Connect the coolant bottle return hose (1).
    Fig 47: Fresh Air Makeup Hose, Air Cleaner Housing & Bolt
    GC0144030Courtesy of CHRYSLER GROUP, LLC
  83. Position the air cleaner housing (3) into the vehicle.
  84. Install the air cleaner housing retaining bolt (2) and tighten to 12 N.m (9 ft. lbs.).
  85. Connect the fresh air makeup hose (1) to the air cleaner housing.
    Fig 48: Inlet Air Temperature (IAT) Sensor Electrical Connector, Air Inlet Hose Assembly & Fasteners
    GC0144029Courtesy of CHRYSLER GROUP, LLC
  86. Position the air inlet hose assembly (5) onto the throttle body and the air cleaner housing.
  87. Secure the air inlet hose assembly retaining grommet onto the ball stud (4).
  88. Tighten the clamp at the air cleaner housing (3) to 5 N.m (44 in. lbs.).
  89. Tighten the clamp (2) at the throttle body to 5 N.m (44 in. lbs.).
  90. Connect the Inlet Air Temperature (IAT) sensor electrical connector (1).
    Fig 49: Cowl Panel, Push-Pins & Fasteners
    GC0080264Courtesy of CHRYSLER GROUP, LLC
  91. Install the strut tower support (6).
  92. Install the cowl panel cover (2). Refer to COVER, COWL PANEL, INSTALLATION .
  93. Install the hood. Refer to HOOD, INSTALLATION .
    Fig 50: Engine Cover
    GC0144028Courtesy of CHRYSLER GROUP, LLC
  94. If removed, install the oil filter and fill the engine crankcase with the specified type and amount of engine oil. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
  95. Fill the cooling system with the specified type and amount of engine coolant. Refer to STANDARD PROCEDURE .
  96. Perform the Refrigerant System Charge procedure. Refer to PLUMBING, STANDARD PROCEDURE .
  97. Position the engine cover (1) and secure the retaining grommets onto the ball studs.
    Fig 51: Negative Battery Cable
    GC0139402Courtesy of CHRYSLER GROUP, LLC
  98. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
  99. Run the engine until it reaches normal operating temperature and check for leaks.
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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