BAD BOYS, WHATCHA GONNA DO NOW?
3.6L V6 Engine Replacement
Long-use fleet vehicles often need added parts and service attention. In the case of engine component repairs, it is often more fiscally prudent to replace an entire engine versus replacing the unit part by part. That’s the focus of this Repair Boost article, specifically in regard to the 3.6L V6 in the Dodge Charger/Challenger police vehicle.
3.6L V6 Engine
The 3.6L V6 engine features variable valve timing (VVT), dual overhead camshafts (DOHC) and a high-pressure, die-cast aluminum cylinder block with steel liners in a 60° configuration. Over the last several years, this engine has become widely used over the entire FCA US LLC product line, including the police version of the Dodge Charger.
Before we discuss the removal of the 3.6L V6 engine, it should be noted that if the engine being removed has experienced a catastrophic failure, or an individual failure with the piston, cylinder bore, engine block or valve, the intake manifold must be replaced with a new manifold.
In order to remove the engine, you’ll need to create space within the engine compartment. First, remove the hood, cowl panel cover and the strut tower support. Perform the fuel pressure release procedure. Next, disconnect and isolate the negative battery cable, and perform a refrigerant system recovery.
Once complete, remove the engine cover and the air cleaner body. Raise the vehicle and remove the belly pan, drain the cooling system and the engine oil. Disconnect the left and right upstream oxygen sensor wire harness connectors. Remove the retaining nuts that connect the catalytic converters to the right and left down pipes.
Remove the starter motor. Rotate the crankshaft in a clockwise direction until the torque converter bolts are accessible through the starter-mounting hole. Remove the six torque converter bolts (see Figure 1).
Disconnect all vacuum lines hoses, including the hoses for the EVAP purge, PCV valve, MAP sensor, crankshaft position sensor and the wiring harnesses. The list of these devices and harnesses can be found in the specific service manual.
Next, remove the upper intake hose, disconnect the fuel supply hose and the cooling fan module. Remove the generator. Mark the variable valve timing solenoid connectors with a paint pen before disconnecting these connectors for easy of re-installation. Also remove the radiator and heater core hoses and A/C compressor and disconnect the transmission cooling lines.
Once the wiring harnesses and hoses have been disconnected and removed, remove the engine using the following sequence. Remove the:
• Two upper side transmission-to-engine retaining bolts
• Side engine-to-transmission bolts
• Transmission dust shield
• Rubber plugs covering the rear oil seal retainer flange bolts
• Four transmission-to-engine oil pan bolts
Lower the vehicle. Remove heater core inlet tube and oil level indicator. Remove the left intake manifold support brackets. Install the left side and right side engine lifting brackets. Reposition the starter wire and main wire harnesses to the rear of the engine compartment.
Next, refer to Figure 2. Position a load-leveling sling (2), such as an OTC® 4305 Engine Load Leveler, between the engine lifting brackets (3) and an engine hoist (1). Support the trans with a jack.
Finally, remove the electric vacuum pump, wire harness, wire harness connector and the quick connect vacuum hose, the heat shields and the left and right engine mount bolts.
Lift the engine from the engine compartment (see Figure 3). While slowly separating the engine from the vehicle, constantly check the position of the engine to ensure that no damage occurs to other engine components or wiring harnesses.
Installing the New Engine
Before installation, some parts have to be removed from the old engine and installed on to the new one including:
• Left and right exhaust down pipes
• Accessory drive belt tensioner
• Left and right engine mounts and engine mount brackets
• Upper intake manifold support bracket
Next, remove the left intake manifold support brackets and install the left side and right side engine lifting brackets. Refer to Figure 2. Position the load-leveling sling (2), such as an OTC® 4305 Engine Load Leveler, or equivalent, between the engine lifting brackets (3) and an engine hoist (1).
Align the two locator dowels into the transmission housing while lowering the engine into the engine compartment. Align the engine mounts, and then install both the left and right engine mount lower retaining bolts. Tighten to the proper torque specifications, and install both engine mount heat shields.
Position the electric vacuum pump in place, then install the two transmission-to-engine retaining bolts. Install the quick connect vacuum hose to the vacuum pump, then connect the wire harness connector.
Remove the engine lifting brackets, and then re-install the left upper intake manifold support brackets. Route the main wire harness and starter wire harness on the engine. Secure the wiring harnesses to the appropriate locations on the engine. Connect and secure the other wiring harnesses that are positioned on the top of the engine.
Remove the jack supporting the transmission. Raise and support the vehicle. Install the four transmission-to-engine oil pan retaining bolts. Install the two rubber plugs covering the rear oil seal retainer flange bolts. Install the side engine-to-transmission retaining bolt and the torque converter dust shield. Then, install the two upper side transmission-to-engine retaining bolts.
Rotate the crankshaft in a clockwise direction and install the six torque converter bolts through the starter-mounting hole. Install the starter. After connecting and securing the wiring harnesses on the bottom side of the engine, install the heat shield over the CKP sensor.
Position both exhaust down pipes to the catalytic converters. Install the retaining nuts and tighten to the correct torque specifications. Connect both upstream oxygen sensor wire harness connectors. Install the belly pan, and then lower the vehicle.
With vehicle back on the ground and the engine installed in the vehicle, the ancillary components can be re-installed in the order these parts were removed. Finally, fill the cooling system with the specified type and amount of coolant and fill the crankcase with the specified type and amount of oil. Start and run the engine until it reaches normal operating temperature. Check for any leaks.
The best part of all, return the vehicle to its place of business knowing you’ve provided the organization with an excellent part and exceptional service.