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Section 13 (3.6L Engine (Service Information)): Removal

WARNING: This page is about a different variant/trim than selected.
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 pressure release procedure. Refer to STANDARD PROCEDURE .
  2. Disconnect and isolate the negative battery cable.
  3. Remove the hood. Refer to HOOD, REMOVAL .
  4. Remove the cowl extension panel. Refer to SILENCER, COWL EXTENSION, REMOVAL .
  5. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
  6. If equipped, remove the front skid plate, the front suspension skid plate, the transmission skid plate and the transfer case skid plate. Refer to PLATE, SKID, TRANSFER CASE, REMOVAL .
  7. Drain the cooling system. Refer to STANDARD PROCEDURE .
  8. Drain the engine oil. Refer to STANDARD PROCEDURE .
  9. Remove the resonator and the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL .
  10. Remove the upper intake manifold and insulator. Refer to MANIFOLD, INTAKE, REMOVAL .
  11. Remove the Exhaust Gas Recirculation (EGR) cooler. Refer to COOLER, EXHAUST GAS RECIRCULATION (EGR), REMOVAL .
  12. Remove the electric vacuum pump and mounting bracket. Refer to PUMP, ELECTRIC VACUUM, REMOVAL .
  13. Remove the A/C compressor retaining bolts and studs, then position aside. Refer to COMPRESSOR, A/C, REMOVAL .
    GC0173709Courtesy of CHRYSLER GROUP, LLC
  14. Disconnect the fuel supply hose from the fuel rail. Refer to FITTING, QUICK CONNECT .
    GC0173642Courtesy of CHRYSLER GROUP, LLC
  15. Remove the heater core return hose from the water pump bypass (1).
  16. Remove the retaining bolts from the engine block (2) and cylinder head (3).
  17. Disconnect the return hose from the engine oil cooler and position the tube assembly aside.
    GC0173792Courtesy of CHRYSLER GROUP, LLC
  18. Remove the heater inlet hose from the coolant crossover (1) and position the heater inlet tube assembly (2) aside.
    GC0173605Courtesy of CHRYSLER GROUP, LLC
  19. Remove the upper radiator hose (1).
    GC0173784Courtesy of CHRYSLER GROUP, LLC
  20. Remove the lower radiator hose (1).
    GC0173782Courtesy of CHRYSLER GROUP, LLC
  21. Remove the coolant bottle inlet hose (1).
  22. Remove the pressurized coolant bottle. Refer to BOTTLE, PRESSURIZED COOLANT, REMOVAL .
  23. Remove the cooling fan module. Refer to FAN, COOLING, REMOVAL .
    GC0173711Courtesy of CHRYSLER GROUP, LLC
  24. Remove the oil dipstick and tube.
    GC0173731Courtesy of CHRYSLER GROUP, LLC
  25. Disconnect the wire harness connector (1) from the Powertrain Control Module (PCM).
  26. Disengage the wire harness retaining clips (2).
    GC0173723Courtesy of CHRYSLER GROUP, LLC
  27. Disconnect the wire harness connector (1) just below the PCM, on the right side frame rail.
  28. Remove the nut (3) and remove the ground cable.
  29. Disengage the wire harness retaining clips (2) and position the harness with the engine.
    GC0173705Courtesy of CHRYSLER GROUP, LLC
  30. Disconnect the positive (1) starter and alternator cable.
  31. Disengage the wire harness from the retaining clips (2) and position with the engine.
  32. Remove the right and left catalytic converters. Refer to CONVERTER, CATALYTIC, REMOVAL .

    .

  33. If equipped with AWD, remove the front axle. Refer to REMOVAL .
  34. Remove the starter. Refer to STARTER, REMOVAL .
    GC0173741Courtesy of CHRYSLER GROUP, LLC
  35. Remove the bolts (1) and the engine mount heat shield from the left engine mount.
    GC0173740Courtesy of CHRYSLER GROUP, LLC
  36. Remove the bolts (1) and the engine mount heat shield from the right engine mount.
  37. Remove the ground strap from the right engine mount bracket.
    GC0173586Courtesy of CHRYSLER GROUP, LLC
  38. Remove the transmission cooler line fastener from the transmission (1) and disengage the retainer (2) from the upper oil pan flange and position lines aside.
    GC0173570Courtesy of CHRYSLER GROUP, LLC
  39. Disconnect the wire harness connector (1) from the transmission.
  40. Disengage the wire harness retainers from the transmission (2).
    GC0173693Courtesy of CHRYSLER GROUP, LLC
  41. Disconnect the wire harness connector from the coolant shut off valve (2).
  42. Remove the oxygen sensor wire harness bracket (1) and position the harness with the engine.
  43. Verify that all wire harness connections and retainers have been disconnected between the engine, transmission and body.
    GC0173680Courtesy of CHRYSLER GROUP, LLC
  44. Remove the fastener and the torque converter dust shield (1).
  45. Disconnect and reposition the power cord from the engine block heater (if equipped).
    GC0144169Courtesy of CHRYSLER GROUP, LLC
  46. Rotate the crankshaft in a clockwise direction until the torque converter bolts (1) are accessible through the starter mounting. Remove the six torque converter bolts (1).
    GC0173593Courtesy of CHRYSLER GROUP, LLC
  47. Remove the side engine to transmission bolt (1).
    GC0173677Courtesy of CHRYSLER GROUP, LLC
  48. Remove four upper transmission to engine bolts (1).
    GC0173609Courtesy of CHRYSLER GROUP, LLC
  49. Remove two rubber plugs (1) covering the rear oil seal retainer flange bolts.
    GC0173659Courtesy of CHRYSLER GROUP, LLC
  50. Remove four transmission to the engine oil pan bolts (1).
  51. Lower the vehicle.
    GC0144309Courtesy of CHRYSLER GROUP, LLC
  52. Install the (special tool #2028010090, Lift Bracket, Engine-Left) (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
  53. Install the (special tool #2028020090, Lift Bracket, Engine-Right) (1) on the RH cylinder head with bolts (2) provided with the Engine Lifting Bracket. Tighten the bolts to 21 N.m (15 ft. lbs.).
    GC0144311Courtesy of CHRYSLER GROUP, LLC
  54. 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).
  55. Support the transmission with a suitable jack.
    GC0173579Courtesy of CHRYSLER GROUP, LLC
  56. Remove the right engine mount nut (1).
    GC0173710Courtesy of CHRYSLER GROUP, LLC
  57. Remove the left engine mount nut (1).
    CAUTION:

    While slowly separating the engine from the vehicle, constant checks must be made to assure proper positioning and that no damage to other components or wiring harnesses occur during separation.

  58. Carefully remove the engine from the engine bay area.
  59. If required, remove the necessary components for installation onto the replacement engine.
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