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

3.6L Engine (Service Information): Removal

GC0160639Courtesy of CHRYSLER GROUP, LLC
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 System Pressure Release procedure. Refer to FUEL DELIVERY, GAS, STANDARD PROCEDURE .
  2. Remove the battery access cover.
  3. Disconnect and isolate the negative battery cable (1).
  4. Remove the engine cover.
  5. Recover the refrigerant from the A/C system. Refer to PLUMBING, STANDARD PROCEDURE .
  6. Remove the air cleaner resonator and clean air hose assembly. Refer to RESONATOR, AIR CLEANER, REMOVAL .
  7. Remove the belly pan and lower splash shields. Refer to BELLY PAN, REMOVAL .
  8. Drain the cooling system. Refer to STANDARD PROCEDURE .
  9. Drain the engine oil. Refer to OIL, STANDARD PROCEDURE .
  10. Remove the crossunder pipe. Refer to PIPE, EXHAUST CROSSUNDER, REMOVAL .
  11. Disconnect the left and right side up stream and down stream oxygen sensor connectors from the main engine harness.
  12. Remove both catalytic converters. Refer to CONVERTER, CATALYTIC, REMOVAL .
  13. Remove the serpentine belt. Refer to BELT, SERPENTINE, REMOVAL .
  14. Remove the A/C compressor from the engine compartment. Refer to COMPRESSOR, A/C, REMOVAL .
  15. If equipped, disconnect and position aside the power cord from the engine block heater.
  16. Remove the starter and starter harness connections. Refer to STARTER, REMOVAL .
  17. Remove the generator wire harness connections and position the battery harness to be removed with engine. Refer to GENERATOR, REMOVAL .
    GC0147040Courtesy of CHRYSLER GROUP, LLC
  18. Disconnect the wire harness retainers (2) from the power steering pump/bracket.
  19. Remove the power steering pump bolts (1) and position aside.
  20. If the transmission is to be eventually separated from the engine, removal of the torque converter bolts and lower transmission mounting bolts are best accomplished at this time.
    GC0147034Courtesy of CHRYSLER GROUP, LLC
  21. Remove the rubber plugs (2) from the bell housing.
  22. Remove the torque convertor bolts access panel (1).
    GC0160540Courtesy of CHRYSLER GROUP, LLC
  23. If required, remove the torque converter-to-driveplate bolts (1).
  24. If required, remove the five transaxle-to-engine lower bolts (2).
    GC0160197Courtesy of CHRYSLER GROUP, LLC
  25. Remove the bolt (3) that secures the transmission cooler lines to the transmission cooler.
    GC0160218Courtesy of CHRYSLER GROUP, LLC
  26. Remove the rear side transmission strut mount bolt (1).
  27. Remove the strut mount bolt (3) at the pivot bracket (4).
  28. Remove the strut from the crossmember.
    GC0147035Courtesy of CHRYSLER GROUP, LLC
  29. Remove the chassis ground at the rear of the transaxle.
  30. Remove the wiring harness retainer (1) from the valve body pan.
  31. Disconnect the transmission solenoid harness connector (2).
  32. Remove both front wheel house splash shields. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, REMOVAL .
  33. Remove both axleshafts and the intermediate shaft. Refer to REMOVAL .
    GC0145659Courtesy of CHRYSLER GROUP, LLC
  34. Remove the lower radiator hose (1).
  35. Remove the bypass hose from the water pump.
  36. Remove the pressurized coolant bottle. Refer to BOTTLE, PRESSURIZED COOLANT, REMOVAL .
  37. Remove the wire harness connections at the Powertrain Control Module (PCM) and position harness to be removed with engine. Refer to MODULE, POWERTRAIN CONTROL (PCM), REMOVAL .
  38. Disconnect the engine harness to body grounds and wire harness retainers and position the harness to be removed with the engine.
  39. Disconnect the engine harness from the Power Distribution Center (PDC) and position with engine for removal. Refer to CENTER, POWER DISTRIBUTION (PDC), REMOVAL .
    GC0160179Courtesy of CHRYSLER GROUP, LLC
  40. Remove the vapor hose (3) from the intake manifold.
  41. Disconnect the vapor hose (1) from the purge valve.
  42. Remove the brake vacuum hose.
    GC0157476Courtesy of CHRYSLER GROUP, LLC
  43. Disengage the upper radiator hose (3) at the radiator.
  44. Remove the heater hoses at the heater core.
    GC0147036Courtesy of CHRYSLER GROUP, LLC
  45. Disconnect the transmission input shaft speed sensor harness connector (1).
    GC0121541Courtesy of CHRYSLER GROUP, LLC
  46. Disconnect the gearshift cable (1) from transaxle manual valve lever (2).
    GC0147037Courtesy of CHRYSLER GROUP, LLC
  47. Disconnect the gearshift cable (5) from the bracket (4).
  48. Disconnect two output shaft speed sensors connectors (2 and 3).
  49. Disengage the wire harness retainer (1) from the gearshift cable bracket.
    GC0147395Courtesy of CHRYSLER GROUP, LLC
  50. Using care, disconnect the fuel line (1) from the fuel rail inlet. Refer to FITTING, QUICK CONNECT, STANDARD PROCEDURE .
  51. Remove the fuel and purge line retainer.
    GC0147013Courtesy of CHRYSLER GROUP, LLC
  52. Raise and position vehicle height to allow Power Train Dolly (special tool #6135, Dolly, Power Train) (3) and Engine Support Cradle (special tool #6710A, Cradle, Engine Support) (2) to be installed under the engine/transaxle assembly.
  53. 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. Lower the vehicle and position cradle until the engine is resting on the posts. Tighten the post mounts to the cradle frame. Secure the engine/transaxle assembly to the dolly/cradle with safety straps (4).
  54. Lower the vehicle so that the weight of the engine and transmission ONLY is on the cradle.
    GC0160720Courtesy of CHRYSLER GROUP, LLC
  55. Remove the nut (1) from the LH engine (transmission) mount bracket.
    NOTE:

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

    GC0160677Courtesy of CHRYSLER GROUP, LLC
  56. Remove three bolts (1) from the RH engine mount bracket (2).
  57. Perform the following steps to remove the transaxle from the engine if required.
  58. Remove the wire harness from the transaxle.
  59. Position a transmission jack under the transaxle. Secure the transaxle to the transmission jack.
    GC0122494Courtesy of CHRYSLER GROUP, LLC
  60. Remove the remaining six transaxle upper bellhousing-to-block bolts (3).
  61. Remove the transaxle (2) and spacer plate from the engine (1).
  62. Remove the upper intake manifold and support brackets. Refer to MANIFOLD, INTAKE, REMOVAL .
  63. Remove the fasteners and the heater core supply tube.
    GC0144309Courtesy of CHRYSLER GROUP, LLC
  64. 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
  65. 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
  66. 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).
  67. Remove the engine from the cradle/dolly fixture.
  68. If required, transfer necessary components for installation onto the replacement engine.
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