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Home › Chrysler › 2004 › Intrepid SE › Repair and Diagnosis › External Pages › Different variant/trim › Section 1 (3.5L Engine (Service Information)) › Engine 3.5L › Removal - Engine Assembly

Removal - Engine Assembly

WARNING: This page is about a different variant/trim than selected.
  1. Release fuel pressure. (Refer to STANDARD PROCEDURE - FUEL SYSTEM PRESSURE REL )
  2. Disconnect negative cable at right strut tower (Fig 1 ).
    Fig 1: Negative Cable Remote Terminal
    G03511860Courtesy of DAIMLERCHRYSLER CORP.
  3. Mark hood position at hinges and remove hood. (Refer to HOOD )
  4. Remove both wiper arms. (Refer to WIPER ARMS )
  5. Remove both right and left cowl screens. (Refer to COWL GRILLE AND SCREEN )
  6. Remove strut tower brace.(Refer to FRONT STRUT TOWER TO TOWER BRACE )
  7. Remove air cleaner assembly with air inlet hose (Fig 2 ).
    Fig 2: Air Cleaner With Inlet Hose
    G03511861Courtesy of DAIMLERCHRYSLER CORP.
  8. Remove upper radiator crossmember. (Refer to GRILLE OPENING REINFORCEMENT )
  9. Disconnect hood release cable from hood latch.
  10. Drain cooling system. (Refer to STANDARD PROCEDURE )
  11. Remove radiator fan. (Refer to RADIATOR FAN )
  12. Remove accessory drive belts. (Refer to ACCESSORY DRIVE )
  13. Disconnect upper radiator hose at engine.
  14. Disconnect lower radiator hose at radiator.
  15. Disconnect engine oil and transmission cooler lines at radiator.
  16. Remove power steering line bracket at left side of radiator.
  17. Remove fasteners attaching air conditioning condenser to radiator.
  18. Remove radiator. (Refer to RADIATOR )
  19. Remove generator. (Refer to GENERATORS & REGULATORS )
  20. Remove power steering pump mounting bolts and set pump aside (Do not disconnect lines). (Refer to PUMP )
  21. Remove air conditioning compressor mounting bolts and set aside (Do not disconnect lines).
  22. Loosen and remove V-Band clamp at right exhaust manifold.
  23. Remove front and rear support bracket fasteners attaching right side catalytic converter down pipe.
  24. Disconnect fuel line. (Refer to FUEL LINES )
  25. Disconnect throttle and speed control cables from bracket. (Refer to THROTTLE CONTROL CABLE )
  26. Disconnect coolant hoses at coolant recovery/pressure container.
  27. Disconnect all vacuum hoses.
  28. Disconnect ground straps at both cylinder heads.
    CAUTION: Upper Intake manifold is a composite design. Therefore, manifold should be removed before lifting engine or damage to the manifold could occur.
  29. Remove upper intake manifold and cover intake manifold openings with tape. (Refer to INTAKE MANIFOLD - UPPER  )
  30. Disconnect heater hoses.
  31. Remove rear throttle body support bracket.
  32. Remove fastener for water pipe at transmission to block bolt.
  33. Remove four upper transmission to block bolts.
  34. Disconnect all electrical connections.
  35. Hoist vehicle.
  36. Drain engine oil.
  37. Remove structural collar and mark flex plate to torque converter position.
  38. Remove bolts holding torque converter to flex plate.
  39. Disconnect both transmission oil cooler line brackets from engine.
  40. Loosen and remove left exhaust manifold V-Band clamp.
  41. For starter removal, loosen the left converter exhaust pipe band clamp and exhaust pipe support bracket at transaxle.
  42. Remove starter. (Refer to STARTER MOTOR )
  43. Remove left engine mount bolts.
  44. Remove right engine mount bolts.
  45. Remove crankshaft position sensor. (Refer to CRANKSHAFT POSITION SENSOR )
  46. Remove two lower transmission to block bolts.
  47. Lower vehicle.
  48. Attach lifting device to engine.
  49. Insert floor jack with small block of wood under transmission pan to support transmission.
  50. Hoist engine from engine compartment.
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