The 3.6 Ltr Pentastar engine found in Jeeps, and Dodge Challenger, Charger, Grand Caravan etc. are known for a leak at the back of the engine and onto the transmission. This is often miss diagnosed as a rear main seal. However it's usual cause is the oil cooler/filter housing.
Our van was leaving the tell tale sign in the driveway. So I will be upgrading the housing to a new aluminum version.
Since the filter housing also holds the oil cooler first we need to drain the coolant.
(https://i.postimg.cc/CKrNCNyT/PXL-20250315-151956238.jpg) (https://postimg.cc/06mDP72c)
Here we can see the oil filter housing buried deep. First thing is to take the engine cover and air intake tube off.
(https://i.postimg.cc/J4661Mn5/PXL-20250315-153257891.jpg) (https://postimg.cc/rK4Cj65D)
(https://i.postimg.cc/q7fNn6qB/PXL-20250315-153302415.jpg) (https://postimg.cc/cvm1GHfP)
Next we need to remove the upper intake. 7 bolts and 4 studs (2 bracket mounts) get removed. Also the rear bracket needs to be removed as well. Under the upper intake there is a piece of foam, put this aside so we remember to put it back on later.
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Next we can remove the lower intake. Disconnect the electrical connectors to the fuel injectors. Chrysler loves to use locking tabs on their connectors. These just get pulled back then the connector tab can be pressed and connector unplugged like normal.
Then you can loosen the 8 bolts holding the intake down. These bolts are "cages" so no fear of losing them if you notice I left the fuel supply line connected. We will just put the whole intake with the line connected to the side.
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(https://i.postimg.cc/NGKyQHxC/PXL-20250315-160600867.jpg) (https://postimg.cc/CdVMNdXb)
Now we can see the culprit, the oil filter housing/cooler. There are 5 bolts in the housing. As well as the two connections for the oil temp sender and the oil pressure sensor. Also the coolant line attached. I found it easier to leave the coolant line attached as you pull the housing out as it gives you more room in the open to lossen the hose clamp and remove the hose.
(https://i.postimg.cc/BbdVdKBw/PXL-20250315-160420721.jpg) (https://postimg.cc/xN35mq7K)
Now comes the task of cleaning up. There will be pool of oil in the valley that needs to be cleaned up as well as cleaning the mating surfaces. If you have a fluid extractor you can suck out the oil. I'm cheap so I just use a battery acid filling tool.
(https://i.postimg.cc/Y984nNMM/PXL-20250315-161501771.jpg) (https://postimg.cc/BLLQtKjV)
Here are the two coolers. The OEM plastic ones are know to crack or warp over time. Also they use plastic plugs that have been known to blow out. The new aluminum version uses steel pipe plugs in place of the plastic plugs.
(https://i.postimg.cc/BnKj9Lx9/PXL-20250315-170542209.jpg) (https://postimg.cc/BjJS2vYM)
(https://i.postimg.cc/RhZWjgTX/PXL-20250315-170548671.jpg) (https://postimg.cc/wynxNcZm)
(https://i.postimg.cc/J4tyxd0h/PXL-20250315-170601543.jpg) (https://postimg.cc/GHwhhKk0)
It's suggested on many forums and by mechanics to use OEM seals and O-rings when reinstalling. The OEM housing comes as one piece so you'll have to use the dorman supplied "figure 8" O-rings for the cooler to housing. All the other seals can be gotten as kits thorough your local Mopar Dealer. Pay attention to the instructions. There is a year difference for the oil return tube older models require the thinner o-ring. The oil cooler gets bolted to the housing at 9 ft lbs. Also you'll need to swap over your oil pressure and temperature sensors as well. The pressure sensors on these are know to fail and/or leak so I got a new OEM one to install.
(https://i.postimg.cc/CLtWnd9K/PXL-20250315-170807218.jpg) (https://postimg.cc/Vdq73sfy)
(https://i.postimg.cc/C1N3R7Vy/PXL-20250315-170812202.jpg) (https://postimg.cc/hzXyw9jM)
Unfortunately I must have forgotten to take a picture of the reinstallation. However the installation is the opposite of removal. Once you have all your mating surface clean the housing can be placed back in. Be sure to follow the torque pattern for the 5 bolts. MotorCity Mechanic does a great video on a replacement of this on YouTube for further instructions. The bolts get torqued to 9 ft lbs.
Next we install the new lower intake seals and reinstall the lower intake. Again there is a torque sequence for this as well. Following the sequence snug them down by hand in order and then using the torque wrench go back and torque them to 71 in lbs in order.
(https://i.postimg.cc/cCMYfKL8/PXL-20250315-190019420.jpg) (https://postimg.cc/MfHvSpRW)
Next reconnect the fuel injector connectors making sure both the connectors and the locking tabs fully engage. Now you can install the upper intake seals and the foam back in place.
(https://i.postimg.cc/BZFQMLfd/PXL-20250315-191111292.jpg) (https://postimg.cc/fkwNbbLK)
Now reinstall the upper intake. Following the sequence tighten the bolts down by hand then follow up with the torque wrench at 89 in lbs.
At this point you can drain the oil, then refill oil and coolant
After that you can reinstall the air intake tube and the engine cover and test run it. The cooler/housing will have air in it. It may take a little while running to get air out of the cooling system.
(https://i.postimg.cc/q7fNn6qB/PXL-20250315-153302415.jpg) (https://postimg.cc/cvm1GHfP)
Once you've confirmed no leaks and proper operation, grab a frosty beverage (if you weren't having them the whole time like me)
Great job Tim. That repair is a must on all those 3.6L engines. I also give credit to Dorman for actually making a part that provides a better solution than the OEM crap put out by MOPAR.
You do a stellar repair and keep that thing on the road as long as possible. Money well spent --
Quote from: goodfellow on Mar 16, 2025, 07:12 PMGreat job Tim. That repair is a must on all those 3.6L engines. I also give credit to Dorman for actually making a part that provides a better solution than the OEM crap put out by MOPAR.
You do a stellar repair and keep that thing on the road as long as possible. Money well spent --
Thanks Ray. These vans while having common issues are very reliable. If you look there are many fleets of these being used for transportation businesses. They are truly a great vehicle.Mandy never wanted a van... She's in love with it. She only wants to get rid of it once the kids are old enough to drive and she can get a 4 door jeep.