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Home >> Jeep >> 2007 >> Wrangler Rubicon, Standard >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> 3.8L Engine (Service Information) >> Installation >> 3.8L Engine

3.8L Engine

Fig 1: 3.8L Structural Cover
GC0064286Courtesy of CHRYSLER LLC
  1. Position the engine in the vehicle.
  2. Install the transmission bell housing to engine mounting bolts. Refer to ManualINSTALLATION or to AutomaticINSTALLATION .
  3. Tighten the engine mount thru bolts. See INSTALLATION .
  4. Install the torque converter bolts. (If equipped). Refer to INSTALLATION .
  5. Install the structural cover (1). See INSTALLATION .
    Fig 2: Location CKP
    GC0064287Courtesy of CHRYSLER LLC
  6. Install the crank position sensor (2) (CKP).
    Fig 3: Starter Mounting 3.8L
    GC0064288Courtesy of CHRYSLER LLC
  7. Install the starter (1). Refer to INSTALLATION .
    Fig 4: Starter Battery Cable 3.8L
    GC0064289Courtesy of CHRYSLER LLC
  8. Install the flex plate inspection cover. (If equipped).
  9. Connect the starter wiring (1). Refer to INSTALLATION .
    Fig 5: O2 Sensors Right Side
    GC0064290Courtesy of CHRYSLER LLC
  10. Connect the knock sensor electrical connector.
  11. Install the left and right exhaust manifolds.
  12. Connect the exhaust system and connect the right side O2 sensors (1,2).
    Fig 6: O2 Sensors Left Side
    GC0064291Courtesy of CHRYSLER LLC
  13. Connect the left side O2 sensors (1,2).
  14. Connect the in block heater (if equipped).
  15. Connect the coolant hose at the engine oil cooler.
    Fig 7: Map Sensor 3.8L
    GC0064292Courtesy of CHRYSLER LLC
  16. Connect the oil pressure sending unit (OPS) wiring harness connector.
  17. Install the upper intake manifold (3). See INSTALLATION .
    Fig 8: EGR Tube Flange
    GC0064293Courtesy of CHRYSLER LLC
  18. Install the EGR tube (1). Refer to INSTALLATION .
  19. Connect the engine vacuum harnesses.
    Fig 9: Map Sensor 3.8L
    GC0064292Courtesy of CHRYSLER LLC
  20. Route the engine harness to the left cylinder head and attach the purge solenoid.
  21. Connect the throttle position (TP), idle air control (IAC) motor, oxygen (H02), cam position (CMP), manifold absolute pressure (MAP) (2), and the engine wiring harness connectors.
    Fig 10: Discharge Line R and I
    GC0064294Courtesy of CHRYSLER LLC
  22. Connect the A/C discharge line (2) at the compressor. Refer to INSTALLATION .
    Fig 11: Suction Line to Compressor
    GC0064295Courtesy of CHRYSLER LLC
  23. Connect the A/C suction line (2) at the compressor and compressor electrical connector. Refer to INSTALLATION .
    Fig 12: Mounting Bolts
    GC0064296Courtesy of CHRYSLER LLC
  24. Install the power steering pump (1). Refer to INSTALLATION .
    Fig 13: Fuel Rail 3.8L
    GC0064297Courtesy of CHRYSLER LLC
  25. Connect the fuel line (4) to the fuel rail.
    Fig 14: Generator Mounting 3.8L
    GC0064298Courtesy of CHRYSLER LLC
  26. Install the generator (3). Refer to INSTALLATION .
    Fig 15: Generator Electronic Connectors 3.8L
    GC0064299Courtesy of CHRYSLER LLC
  27. Reconnect the generator wiring. (1, 2). Refer to INSTALLATION .
  28. Install the drive belt.
    Fig 16: Throttle Body 3.8L
    GC0064300Courtesy of CHRYSLER LLC
  29. Connect the radiator, coolant reservoir and heater hoses.
  30. Connect the throttle wiring harness (ETC) (3).
    Fig 17: PCV Valve Location 3.8L
    GC0064301Courtesy of CHRYSLER LLC
  31. Install the PCV hose (1).
  32. Fill the cooling system. Refer to STANDARD PROCEDURE .
    Fig 18: Internal Air Temperature Sensor 3.8L
    GC0064302Courtesy of CHRYSLER LLC
  33. Install the air cleaner housing, inlet hose (1) and inlet air temp sensor (IAT) (2). See INSTALLATION .
  34. Evacuate and recharge A/C system. Refer to STANDARD PROCEDURE .
  35. Install new oil filter. Fill engine crankcase with proper oil to correct level. Refer to SPECIFICATIONS .
    Fig 19: Front Splash Shield
    GC0064303Courtesy of CHRYSLER LLC
  36. Install the front splash shield (1).
  37. Connect negative cable to battery.
  38. Start engine and run until operating temperature is reached.
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