2.4L MULTIAIR: Removal

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Disconnect and isolate the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), disconnect the IBS connector first before disconnecting the negative battery cable.
Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .

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Remove the right front half shaft. Refer to REMOVAL AND INSTALLATION or REMOVAL AND INSTALLATION .
NOTE:
Do not pry the inner joint from the PTU or damage may occur to the joint or shaft. To remove the front half shaft from the PTU, expand the snap ring (see figure below) on the shaft using snap ring pliers and remove the inner joint. The joint should slide off by hand with the snap ring expanded.
Remove the rear propeller shaft. Refer to REMOVAL AND INSTALLATION .

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Visually inspect the end of the quill shaft (2) through the weep hole (1) in the PTU. There should be a 3mm gap of empty space between the end of the shaft (2) and the edge of the hole if the quill shaft is pushed in completely. If there is no empty space the quill shaft has become disengaged from the transmission and should be replaced before installing or replacing the PTU.

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Remove the front exhaust pipe support bracket bolts (1).
Remove the exhaust pipe support bracket bolt (2).
Remove the nuts (3) and disengage the exhaust pipe from the catalytic converter and position the exhaust pipe aside.

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Disconnect the wire harness connector (1) from the Power Transfer Unit (PTU) actuator.
Remove the intake manifold support bracket nuts and the bracket (2).

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Remove the bolts (1a), (1b) and remove the PTU support bracket (1c).
Remove the PTU vent tube.

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Loosen the PTU bolts (1a) to allow the PTU (1b) to slightly pivot.

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Remove the intake manifold bracket stud (1) from the intake manifold.

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Remove the engine mount to transmission bracket bolt (1) and move the engine forward approximately one inch.

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NOTE:
The top PTU bolt will stay in the vehicle on the PTU and will be removed with the PTU.
Completely remove three PTU bolts (1a) and remove the PTU (1b) from the vehicle.

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Remove and DISCARD the O-ring.

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If required, remove the bolts (1a) and remove the PTU actuator (1b).