FixVault

Removal - Engine

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.

Fig 1: Engine Cover - 2.4L
GC0084906Courtesy of CHRYSLER GROUP, LLC
  1. Remove the hood. Refer to HOOD, REMOVAL .
  2. Remove the engine cover (1).
    Fig 2: Ignition Coils, Air Hose, Fuel Line, Injectors & PCV Hose
    GC0084907Courtesy of CHRYSLER GROUP, LLC
  3. Perform the fuel pressure release procedure. Refer to FUEL SYSTEM PRESSURE RELEASE PROCEDURE .
  4. Disconnect the fuel line (3) from the fuel rail. Refer to FITTING, QUICK CONNECT .
    Fig 3: Retainers, Fresh Air Inlet Duct & Air Cleaner Body
    GC0145275Courtesy of CHRYSLER GROUP, LLC
  5. Unlock the retainers (2) and remove the fresh air inlet duct (3) from air cleaner body (1).
    Fig 4: Electrical Connectors, PCM, Three Mounting Bolts & Ground Wire
    GC0145274Courtesy of CHRYSLER GROUP, LLC
  6. Disconnect and isolate the negative battery cable.
  7. Unlock and disconnect the electrical connectors (2) from the PCM (4).
  8. Remove the mounting bolt (3) and ground wire (1).
    Fig 5: Air Cleaner Body, Air Inlet Tube & Make-Up Air Hose
    GC0145278Courtesy of CHRYSLER GROUP, LLC
  9. Remove the air inlet tube (2) from the air cleaner body (1).
  10. Disconnect the make-up air hose (3) from the air cleaner body.
  11. Remove the support bracket bolt from the strut tower.
  12. Pull upward to disengage the pins from the rubber grommets and remove the air cleaner body (1).
    Fig 6: Battery Tray
    GC0098682Courtesy of CHRYSLER GROUP, LLC
  13. Remove the battery and the battery tray (1). Refer to TRAY, BATTERY, REMOVAL .
  14. Discharge air conditioning system, if equipped. Refer to PLUMBING, STANDARD PROCEDURE .
  15. Drain cooling system. Refer to STANDARD PROCEDURE .
    Fig 7: Windshield Washer Reservoir, Power Steering Reservoir & Coolant Reservoir
    GC0098683Courtesy of CHRYSLER GROUP, LLC
  16. Remove the coolant reservoir (3).
  17. Remove the power steering reservoir (2).
  18. Remove the windshield washer reservoir (1).
    Fig 8: Coolant Temperature Sensor, Capacitor Electrical Connector & Coolant Adapter
    GC0084911Courtesy of CHRYSLER GROUP, LLC
  19. Remove coolant hoses from coolant adapter (3).
  20. Disconnect coolant temperature sensor connector (1) and capacitor connector (2).
    Fig 9: Radiator Hose Support
    GC0084912Courtesy of CHRYSLER GROUP, LLC
  21. Remove upper radiator hose support (1).
    Fig 10: Ignition Coils, Air Hose, Fuel Line, Injectors & PCV Hose
    GC0084907Courtesy of CHRYSLER GROUP, LLC
  22. Disconnect coils (1), injectors (4), cam sensors, oil temperature sensor, and oil control valve electrical connectors and reposition harness.
  23. Remove PCV hose (5) from valve cover.
    Fig 11: Throttle Body Support
    GC0098684Courtesy of CHRYSLER GROUP, LLC
  24. Remove harness from intake (2).
  25. Remove throttle body support bracket (1).
  26. Remove vacuum lines from intake manifold.
  27. Disconnect electronic throttle control and manifold flow control valve electrical connectors.
    Fig 12: Intake Manifold Bolt Removal & Tightening Sequence
    GC0098575Courtesy of CHRYSLER GROUP, LLC
  28. Remove dipstick.
  29. Remove intake bolts (1 - 5) and remove intake.
  30. Disconnect coolant temperature sensor at block, knock sensor, oil pressure sensor, generator, starter, block heater (if equipped), A/C compressor (if equipped), and block ground.
  31. Remove accessory drive belt.
    Fig 13: Power Steering Line Support
    GC0098685Courtesy of CHRYSLER GROUP, LLC
  32. Remove power steering line support at engine mount (1).
    Fig 14: P/S Hose Support - FWD
    GC0084913Courtesy of CHRYSLER GROUP, LLC
  33. On FWD vehicles, remove power steering hose support from exhaust manifold (2).
  34. Remove power steering pump and set aside.
    Fig 15: Ground Strap
    GC0098686Courtesy of CHRYSLER GROUP, LLC
  35. Remove ground strap (1) at right strut tower.
  36. Raise vehicle.
    Fig 16: Damper Removal
    GC0084914Courtesy of CHRYSLER GROUP, LLC
  37. Install Damper holder (special tool #9707, Holder, Vibration Damper) (1).
  38. Remove crankshaft damper bolt and remove damper.
  39. Remove right wheel.
  40. Remove right splash shield.
    Fig 17: Oil Drain Plug
    GC0084915Courtesy of CHRYSLER GROUP, LLC
  41. Drain oil (2).
    Fig 18: Exhaust Pipe To Manifold, Heat Shield & Oxygen Sensor Electrical Connector
    GC0084916Courtesy of CHRYSLER GROUP, LLC
  42. On AWD vehicles, remove maniveter. Refer to MANIFOLD, EXHAUST, REMOVAL .
  43. Remove exhaust pipe to exhaust manifold bolts (1).
  44. Disconnect oxygen sensor connector (3).
    Fig 19: Exhaust Pipe & Suitable Strap
    GC0084917Courtesy of CHRYSLER GROUP, LLC
  45. On FWD vehicles, pull the exhaust pipe (1) rearward with a suitable strap (2).
    Fig 20: Inspection Cover
    GC0098687Courtesy of CHRYSLER GROUP, LLC
  46. Remove inspection cover (1) and mark torque converter to flywheel.
    Fig 21: Modular Clutch To Flex Plate Bolts
    GC0084918Courtesy of CHRYSLER GROUP, LLC
  47. On vehicles equipped with an automatic transaxle, remove torque converter bolts (1).
  48. On vehicles equipped with an manual transaxle, remove modular clutch bolts (1).
  49. Remove lower bellhousing bolts (2).
    Fig 22: A/C Compressor
    GC0084919Courtesy of CHRYSLER GROUP, LLC
  50. Remove A/C compressor (1).
  51. Remove generator and lower idler pulley.
    Fig 23: Crankshaft Position Sensor
    GC0098688Courtesy of CHRYSLER GROUP, LLC
  52. Disconnect crankshaft position sensor (2) electrical connector.
  53. Remove crankshaft position sensor (2).
    Fig 24: Identifying Lift Chain
    GC0084920Courtesy of CHRYSLER GROUP, LLC
  54. Remove exhaust variable valve timing solenoid.
  55. Install engine lift chain (1).
  56. Install engine lift chain to rear lift hook.
  57. Install appropriate engine lifting crane.
    Fig 25: Right Engine Mount
    GC0098689Courtesy of CHRYSLER GROUP, LLC
  58. Remove engine mount through bolt (4).
  59. Remove right engine mount bracket retaining bolts (3).
  60. Remove engine mount adapter (2).
  61. Raise engine away from vehicle.