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Section 2 (3.2L Engine (Service Information)): Installation

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.

NOTE:

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

GC0147013Courtesy of CHRYSLER GROUP, LLC
  1. Position the engine to the Dolly, Power Train (special tool #6135, Dolly, Power Train) (3) and the Cradle, Engine Support (special tool #6710A, Cradle, Engine Support).
  2. If required, loosen the cradle assembly from the power train dolly to allow for adjustment.
  3. Position the Adapter (special tool #6848-3, Adapter) post (2) to the engine locating holes (1) on the engine block and oil pan rail.
  4. Lower the engine until it is resting on the posts of the adapters.
  5. If required, tighten the engine cradle adapter to the cradle frame.
  6. Secure the engine assembly to the dolly/cradle with safety straps (4).
    NOTE:

    Perform the following steps to install the transmission to the engine if required.

    GC0159743Courtesy of CHRYSLER GROUP, LLC
  7. If removed, position the flexplate (1) to the crankshaft. Tighten the bolts to the proper torque specification. Refer to (TORQUE SPECIFICATIONS ).
  8. Position the spacer plate (2) to the engine.
  9. Align the transmission (4) to the engine.
  10. Install the upper transmission to engine bolts (3). Tighten the bolts to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
  11. Position the engine/transmission assembly under the vehicle.
  12. Slowly lower the vehicle in small increments while inspecting each interval for potential engine or transmission contact to vehicle components. Move the cradle/dolly fixture as necessary to allow for clearance.
    GC0158452Courtesy of CHRYSLER GROUP, LLC
  13. Hand start the right side engine mount bolts (2, 3) to engine mount bracket. Tighten the bolt to the proper torque specification. Refer to (TORQUE SPECIFICATIONS ).
    GC0159450Courtesy of CHRYSLER GROUP, LLC
  14. Hand start the left side engine mount bolts (1) to transmission mount bracket. Tighten the bolt to the proper torque specification. Refer to (TORQUE SPECIFICATIONS ).
  15. Remove the dolly/cradle safety straps.
  16. Raise vehicle enough to allow the dolly/cradle fixture to be removed from under the vehicle.
  17. Lower the vehicle.
    GC0159235Courtesy of CHRYSLER GROUP, LLC
  18. Connect the transmission harness connector (1) into transmission.
  19. Rotate the lock lever (1) clockwise on the transmission connector.
    GC0160099Courtesy of CHRYSLER GROUP, LLC
  20. Press the shift cable (2) onto the mount bracket (1).
  21. Press the shift cable onto the transmission manual shift valve lever.
  22. If removed, install the electric vacuum pump and mounting bracket. Refer to INSTALLATION 3.2L .
    GC0159634Courtesy of CHRYSLER GROUP, LLC
  23. Install the ground strap (1) to right side upper frame (3). Tighten the nut (2) to proper torque specification. Refer to (TORQUE SPECIFICATIONS ).
  24. Install the wiring harness retainers (2) to the lower air box housing.
    GC0160019Courtesy of CHRYSLER GROUP, LLC
  25. Install the suction/liquid line manifold (2) to the Internal Heat Exchanger (IHX) (1) and install the nut (3). Tighten the nut to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
    GC0159788Courtesy of CHRYSLER GROUP, LLC
  26. Install the battery tray. Tighten the bolts (1, 2) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
    GC0159552Courtesy of CHRYSLER GROUP, LLC
  27. Connect the main engine harness connector (4) to the body side harness at the left front upper frame.
    GC0159227Courtesy of CHRYSLER GROUP, LLC
  28. Install the main engine harness connector (2) to the battery tray.
  29. Install the engine harness retainer (3) onto the battery tray.
  30. If equipped, install the engine block heater electrical cord clip (1) to the battery tray.
    GC0159813Courtesy of CHRYSLER GROUP, LLC
  31. Connect the engine harness to the Power Distribution Center (PDC) base. Hand tighten the bolt (2).
  32. Install the PDC (1) into proper position on the lower cover.
  33. Press down on the PDC until the tabs lock.
    GC0160052Courtesy of CHRYSLER GROUP, LLC
  34. Position the positive cables onto the Z-case fuse array at the PDC.
  35. Install and hand tighten the nuts (2) that secure the cables to the PDC case.
  36. Install the PDC cover into proper position on the PDC assembly.
    GC0159262Courtesy of CHRYSLER GROUP, LLC
  37. Connect the engine harness connectors (2) to the Powertrain Control Module (PCM).
  38. Position the ground cable (4) to the PCM mounting stud. Hand tighten the nut (3).
  39. Raise and support the vehicle.
    GC0160024Courtesy of CHRYSLER GROUP, LLC
  40. Install the lower battery tray bolts (3). Tighten the bolt to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
    GC0159945Courtesy of CHRYSLER GROUP, LLC
  41. Connect the oil cooler lines (1) to transmission.
    GC0160135Courtesy of CHRYSLER GROUP, LLC
  42. If required, install the torque converter-to-flexplate bolts (1). Tighten the bolts to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0159240Courtesy of CHRYSLER GROUP, LLC
  43. If required, install the transaxle torque converter housing dust cover (2) and rubber plugs.
  44. If required, install the lower transmission-to-engine bolts and tighten to proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0156343Courtesy of CHRYSLER GROUP, LLC
  45. Connect the heater core supply hose (2).
  46. Connect the heater core return hose (3).
    GC0147007Courtesy of CHRYSLER GROUP, LLC
  47. If the gaskets need replacing, position new gasket onto the manifold flange and install the lower retainer plate (2). Loosely install all four bolts to align the gasket. Tighten the lower retainer (2) bolts to the proper torque specification. Refer to (TORQUE SPECIFICATIONS ).
  48. Remove the upper catalytic converter flange bolts.
  49. Install the crossmember assembly. Refer to INSTALLATION .
  50. Position the rear catalytic converter to the cylinder head.
  51. If equipped, install the PTU to the transmission

    Refer to INSTALLATION .

    NOTE:

    FWD  support bracket shown in illustration. AWD  support bracket similar.

    GC0159750Courtesy of CHRYSLER GROUP, LLC
  52. Install the intermediate shaft support bracket (1). Tighten the bolts (2, 3) to the proper torque specification. Refer to (TORQUE SPECIFICATIONS ).
  53. Install the cross under pipe. Refer to 3.2L .
    GC0160127Courtesy of CHRYSLER GROUP, LLC
  54. Align the Y-pipe (4) to the rear catalytic converter. Tighten the nuts (5) to the proper torque specification. Refer to (TORQUE SPECIFICATIONS ).
    GC0159205Courtesy of CHRYSLER GROUP, LLC
  55. Install the ground strap (1) to the transmission. Tighten the bolt (2) to the proper torque specification. Refer to (TORQUE SPECIFICATIONS ).
  56. Partially lower the vehicle.
    GC0158453Courtesy of CHRYSLER GROUP, LLC
  57. Install the lower radiator hose (2) to the water pump.
  58. Install the heater hose (1) to the water pump.
  59. Install both axleshafts. Refer to INSTALLATION .
  60. Install both front tire and wheel assemblies. Refer to INSTALLATION .
    GC0159475Courtesy of CHRYSLER GROUP, LLC
  61. Install the outer battery tray (1) to frame. Tighten the bolt (2) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
    GC0160008Courtesy of CHRYSLER GROUP, LLC
  62. Install the bolt (2) that secures the washer solvent bottle to the battery tray. Tighten the bolt to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
  63. Install the wiring harness retainer (1) onto the battery tray.
  64. Install the inner wheel house splash shields. Refer to INSTALLATION .
  65. Install the pressurized coolant bottle supply tube.
  66. Install the front bumper fascia. Refer to FASCIA, FRONT, INSTALLATION .
  67. Raise the vehicle.
  68. Install the engine belly pan (3). Refer to BELLY PAN, INSTALLATION .
  69. Lower the vehicle.
    GC0159619Courtesy of CHRYSLER GROUP, LLC
  70. Install the upper radiator hose (2) to the radiator inlet pipe (1).
    GC0159818Courtesy of CHRYSLER GROUP, LLC
  71. Install the A/C lines (1) to the IHX. Tighten the nuts (2) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
    GC0147395Courtesy of CHRYSLER GROUP, LLC
  72. Connect the fuel line (1) to the fuel rail inlet.
    GC0160133Courtesy of CHRYSLER GROUP, LLC
  73. Install the upper catalytic convertor flange bolts (5). Tighten the bolts to the proper torque specification. Refer to (TORQUE SPECIFICATIONS ).
    GC0159493Courtesy of CHRYSLER GROUP, LLC
  74. Connect both right side (rear) O2 sensor harness connectors (1, 2).
  75. Install the air cleaner resonator. Refer to RESONATOR, AIR CLEANER, INSTALLATION .
  76. Install the air cleaner body. Refer to BODY, AIR CLEANER, INSTALLATION .
  77. Install the purge control solenoid. Refer to SOLENOID, EVAPORATIVE EMISSIONS PURGE, INSTALLATION .
    GC0159542Courtesy of CHRYSLER GROUP, LLC
  78. Align the intermediate shaft (1) to the steering gear shaft (2).
  79. Install a NEW  pinch bolt (3). Tighten the bolt to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
  80. Fill the engine crankcase with proper oil to correct level.
  81. Evacuate and recharge the A/C system. Refer to PLUMBING, STANDARD PROCEDURE .
  82. Fill the cooling system. Refer to COOLANT SYSTEM AIR EVACUATION .
  83. Install the battery. Refer to BATTERY, INSTALLATION .
    GC0159742Courtesy of CHRYSLER GROUP, LLC
  84. Install the engine cover (1) onto the mounting posts (2).
  85. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to ADDING ADDITIONAL COOLANT .
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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