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Removal - Engine Assembly

  1. Release fuel pressure. (Refer to FUEL SYSTEM PRESSURE RELEASE )
  2. Disconnect negative cable at remote jumper terminal located at right strut tower (Fig 1).
    Fig 1: Disconnecting Negative Cable Remote Terminal
    G00990697Courtesy of DAIMLERCHRYSLER CORP.
  3. Mark hood position at hinges and remove hood.
  4. Drain cooling system. (Refer to STANDARD PROCEDURE - COOLING SYSTEM DRAINING )
  5. Remove both wiper arms. (Refer to WIPER ARMS )
  6. Remove right and left cowl screens. (Refer to Fig 2)
    Fig 2: Removing & Installing Cowl Grille & Screen
    G00380986Courtesy of DAIMLERCHRYSLER CORP.
  7. Remove strut tower brace. (Refer to Fig 3)
    Fig 3: Removing & Installing Strut Tower Brace
    G00380987Courtesy of CHRYSLER CORP.
  8. Remove air cleaner assembly and air inlet hose (Fig 4).
    Fig 4: Removing Air Cleaner & Inlet Hose
    G00990698Courtesy of DAIMLERCHRYSLER CORP.
  9. Remove radiator upper crossmember.
    1. Mark bolt locations on the radiator upper crossmember.
    2. Remove bolts attaching windshield washer bottle and speed servo, if equipped. (Refer to Fig 5.)
      Fig 5: Removing Radiator Upper Crossmember
      G00380985Courtesy of CHRYSLER CORP.
    3. Remove headlamp jackscrews both sides.
    4. Remove fasteners attaching upper bumper fascia.
    5. Remove bolts attaching the upper forward edge of upper radiator closure panel.
    6. Remove bolts attaching upper radiator closure panel
    7. Disconnect hood latch cable from hood latch.
    8. Remove upper radiator closure panel from vehicle.
    9. For replacement of upper radiator upper crossmember, remove hood latch, and any other hardware.
  10. Disconnect hood release cable from hood latch.
  11. Remove radiator fan. (Refer to RADIATOR FAN ASSEMBLY )
  12. Disconnect radiator upper hose at engine.
  13. Disconnect radiator lower hose at radiator.
  14. Remove radiator. (Refer to RADIATOR )
  15. Remove accessory drive belts. (Refer to DRIVE BELTS - 2.7L )
  16. Remove power steering pump mounting bolts and set pump aside. (Refer to REMOVAL - PUMP (2.7L ENGINE) )
    NOTE: Generator can be removed with engine assembly.
  17. Disconnect A/C compressor electrical connector.
  18. Remove A/C compressor mounting bolts and set compressor aside. (Refer to A/C COMPRESSOR - MANUAL A/C or A/C COMPRESSOR - AUTO A/C )
  19. Loosen and remove V-Band clamps at exhaust manifolds.
  20. Disconnect throttle and speed control cables.
  21. Disconnect coolant hoses at coolant pressure/recovery container.
  22. Disconnect heater hoses.
  23. Perform fuel pressure release procedure and disconnect fuel line. (Refer to FUEL SYSTEM PRESSURE RELEASE and FUEL LINE DISCONNECT FITTINGS )
  24. Disconnect all vacuum lines and electrical connectors.
  25. Disconnect all ground straps attaching to engine.
  26. Hoist vehicle and drain engine oil.
  27. Remove fasteners supporting catalytic converter down pipes at front and rear mounts.
  28. Remove structural collar. (Refer to STRUCTURAL COLLAR/COVER )
  29. Mark flex plate to torque converter position. Remove torque converter bolts.
  30. Disconnect both transaxle cooler line brackets from engine.
  31. Remove starter. (Refer to STARTER MOTOR )
  32. Remove crankshaft position sensor. (Refer to CRANKSHAFT POSITION SENSOR )
  33. Remove the two lower transaxle to block bolts.
  34. Lower vehicle.
  35. Remove screws attaching fuel line and electrical harness to the throttle body bracket.
  36. Remove the fasteners attaching the following brackets to the transaxle to block double-ended bolts:
    • Electrical harness attaching bracket.
    • Transaxle shift cable attaching bracket.
    • Throttle body support bracket.
  37. Remove the upper transaxle to block bolts.
  38. Remove right and left engine mount isolator to engine mount bracket fasteners.
    CAUTION: Intake manifolds and cylinder head covers are a composite design. Therefore, care should be taken when lifting the engine from engine compartment.
  39. Attach Special Tool 8342, Engine Lifting Fixture to engine at the locations shown in (Fig 6).
    Fig 6: Identifying Engine Lifting Fixture
    G00990699Courtesy of DAIMLERCHRYSLER CORP.
  40. Support transaxle with a floor jack.
  41. Hoist engine from engine compartment.
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