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Removal And Installation - AWD: Installation

WARNING: This page is about a different car, the 2022 Chrysler Voyager and 2022 Chrysler Pacifica. However, it is still accessible from the selected car via links, so may be relevant.
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. If required, remove the upper intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL AND INSTALLATION .
    GC0144309Courtesy of CHRYSLER GROUP, LLC
  2. Install the special tool (#2028020090, Lift Bracket, Engine-Left) (1) on the LH cylinder head with bolts (2) provided with the Engine Lifting Bracket. Tighten the bolts to the proper torque specifications. Refer to TORQUE SPECIFICATIONS  .
    GC0144310Courtesy of CHRYSLER GROUP, LLC
  3. Install the special tool (#2028010090, Lift Bracket, Engine-Right) (1) on the RH cylinder head with bolts (2) from the Engine Lifting Bracket. Tighten the bolts to the proper torque specifications. Refer to TORQUE SPECIFICATIONS  .
    GC0144311Courtesy of CHRYSLER GROUP, LLC
  4. 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).
    GC0147013Courtesy of CHRYSLER GROUP, LLC
  5. Position the engine/transaxle assembly on the Power Train Dolly special tool (#6135, Dolly, Power Train) (3) and Engine Support Cradle special tool (#6710A, Cradle, Engine Support) (2).
  6. 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. Tighten the post mounts to the cradle frame. Secure the engine assembly to the dolly/cradle with safety straps (4). Remove the engine lifting brackets.
  7. Install the transaxle to the engine if required. Secure with six transaxle upper bellhousing-to-block bolts tightened to the proper torque specifications. Refer to TORQUE SPECIFICATIONS  .
    NOTE:

    If installing a replacement engine, transfer the necessary components such as engine mount brackets, block heater, accessories, heater hoses and tubes to the replacement engine.

  8. Position the engine/transaxle assembly under the vehicle. Slowly lower the vehicle in short length spans. Inspect at each interval for potential engine or transaxle contact to vehicle components. Move the cradle/dolly fixture as necessary to allow for clearance.
    GC0177993Courtesy of CHRYSLER GROUP, LLC
  9. Install the four bolts (2) to the RH engine mount bracket and tighten bolts to the proper torque specifications. Refer to TORQUE SPECIFICATIONS  .
    GC0178196Courtesy of CHRYSLER GROUP, LLC
  10. Install the three bolts to the LH engine (transmission) mount bracket and tighten bolts to the proper torque specifications. Refer to TORQUE SPECIFICATIONS  .
    GC0177674Courtesy of CHRYSLER GROUP, LLC
  11. Install the upper radiator hose (1).
    GC0177681Courtesy of CHRYSLER GROUP, LLC
  12. Connect the Exhaust Gas Recirculation (EGR) cooler vent hose (1) to the pressurized coolant bottle.
    GC0178095Courtesy of CHRYSLER GROUP, LLC
  13. Connect the fuel supply line (2) at the FRPS (Fuel Rail Pressure Sensor). Refer to FUEL DELIVERY, GAS, STANDARD PROCEDURE .
  14. Connect the FRPS wire harness connector (1).
    GC0178234Courtesy of CHRYSLER GROUP, LLC
  15. Connect the fuel vapor hose (1).
    GC0177636Courtesy of CHRYSLER GROUP, LLC
  16. Connect the brake vacuum hose to the upper intake manifold (1) and engage the hose (2) into the intake manifold retaining clips.
    GC0177512Courtesy of CHRYSLER GROUP, LLC
  17. Position the brake vacuum hose (2) into the engine compartment, connecting the retaining clips (1).
    GC0177523Courtesy of CHRYSLER GROUP, LLC
  18. Install the electric vacuum pump and mounting bracket. Refer to PUMP, VACUUM, REMOVAL AND INSTALLATION .
  19. Connect the brake vacuum hose to the electric vacuum pump (1).
  20. Secure the brake vacuum hose into all retaining clips (2).
    GC0177449Courtesy of CHRYSLER GROUP, LLC
  21. Connect the heater core hoses (1).
    GC0178387Courtesy of CHRYSLER GROUP, LLC
  22. Connect the Manual Park Release (MPR) cable onto the lever on the transmission (2) and the retaining bracket (1).
    GC0177527Courtesy of CHRYSLER GROUP, LLC
  23. Connect the powertrain wire harness connector to the body harness connector (1) above the transmission and engage harness into the transmission bracket (2).
    GC0177718Courtesy of CHRYSLER GROUP, LLC
  24. Connect the wire harness connector to the powertrain control module (1).
    GC0177835Courtesy of CHRYSLER GROUP, LLC
  25. Connect the wire harness (1) connector onto the relay control box.
  26. Fasten the ground wire to the left front wheelhouse panel (2).
  27. Install the resonator. Refer to RESONATOR, AIR CLEANER, REMOVAL AND INSTALLATION .
  28. Install the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL AND INSTALLATION .
  29. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
    GC0177721Courtesy of CHRYSLER GROUP, LLC
  30. If required, install the transaxle to oil pan bolts (1) and tighten to the proper torque specifications. Refer to TORQUE SPECIFICATIONS  .
    GC0177423Courtesy of CHRYSLER GROUP, LLC
  31. Install the two rubber plugs (1) covering the rear oil seal retainer flange bolts.
    GC0178298Courtesy of CHRYSLER GROUP, LLC
  32. If required, install the torque converter-to-driveplate bolts.
  33. If required, install the transaxle torque converter housing dust cover (1).
    GC0177952Courtesy of CHRYSLER GROUP, LLC
  34. Position the positive battery cable to the starter and alternator, engaging the harness into the retaining clips.
  35. Tighten the positive battery cable to starter retaining nut to the proper torque specifications. Refer to TORQUE SPECIFICATIONS  .
  36. Tighten the positive battery cable to alternator retaining nut (1) to the proper torque specifications. Refer to TORQUE SPECIFICATIONS  .
  37. Connect the power cord to the engine block heater (if equipped).
    GC0177991Courtesy of CHRYSLER GROUP, LLC
  38. Connect the wire harness connectors (2) to the power steering gear and engage the harness into the retaining bracket (1).
  39. Connect the transmission oil cooler lines to the transaxle. Refer to TUBES AND HOSES, TRANSMISSION OIL COOLER, REMOVAL AND INSTALLATION .
    GC0178290Courtesy of CHRYSLER GROUP, LLC
  40. Install the A/C suction (1) and discharge (2) lines to the compressor and tighten to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .
    GC0177836Courtesy of CHRYSLER GROUP, LLC
  41. Install the lower radiator hose (2) onto the water pump.
    GC0178262Courtesy of CHRYSLER GROUP, LLC
  42. Install the heater core return hose (1) onto the lower radiator coolant tube.
  43. Install both catalytic converters. Refer to CONVERTER, CATALYTIC, REMOVAL AND INSTALLATION .
  44. Remove the Power Transfer Unit (PTU). Refer to REMOVAL AND INSTALLATION .
  45. Install both front axle shafts. Refer to REMOVAL AND INSTALLATION .
  46. Install the front suspension crossmember. Refer to CROSSMEMBER, FRONT SUSPENSION, REMOVAL AND INSTALLATION .
  47. Lower the vehicle.
  48. Fill engine crankcase with proper oil to correct level.
  49. Fill cooling system. Refer to STANDARD PROCEDURE - FILLING - 3.6L .
  50. Install the engine cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION .
  51. Connect the negative battery cable.
  52. Evacuate and recharge Air Conditioning system. Refer to PLUMBING, FRONT, STANDARD PROCEDURE .
  53. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to STANDARD PROCEDURE .
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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