CAUTION: If the engine encounters a catastrophic failure, the engine oil cooler must be replaced or damage to the new engine and/or components could result.
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.
1. Remove the hood. Refer to HOOD, REMOVAL .
2. Remove the cowl panel cover (1). Refer to COVER, COWL PANEL, REMOVAL .
3. Remove the strut tower support (6).
4. Lift the engine cover retaining grommets off the ball studs and remove the engine covers (1).
5. Perform the fuel system pressure release procedure. Refer to FUEL DELIVERY, GAS, STANDARD PROCEDURE .
6. Disconnect and isolate the negative battery cable (1).
NOTE:
Remove the intake manifold and throttle body as an assembly.
7. Remove the intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL.
NOTE:
The engine must be at room temperature before removing the Oil Control Valve.
8. Disconnect the Oil Control Valve electrical connector (1).
9. Remove the Oil Control Valve retaining bolt (2).
10. Rotate the Oil Control Valve (3) to break the seal then pull the Oil Control Valve straight out.
CAUTION: Do not let the tensioner arm snap back to the free arm position, sever damage may occur to the tensioner.
11. Rotate the accessory drive belt tensioner (8) clockwise until it contacts the stop and remove the accessory drive belt (2), then slowly rotate the tensioner into the free arm position.
12. Remove the cooling fan (1). Refer to FAN, COOLING, REMOVAL .
13. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
14. Remove the belly pan retainers (1) and remove the belly pan.
15. Drain the cooling system. Refer to STANDARD PROCEDURE .
16. Drain the engine oil. Refer to STANDARD PROCEDURE .
17. Remove the A/C compressor (3). Refer to COMPRESSOR, A/C, REMOVAL .
18. Remove both left/right engine mount heat shield (4) retaining nuts (3) and remove the heat shields.
19. Remove both left/right engine mount to frame retaining bolts (2).
20. Disconnect the transmission oil cooler lines from their retainers at the oil pan.
21. Remove the lower radiator hose (1).
NOTE:
Two knock sensors are used. Each sensor is bolted to the outside of the engine block below the exhaust manifold.
NOTE:
Left side shown in illustration, right side similar.
22. Remove the heat shields from both knock sensors (shield snaps on/off sensor).
23. Disconnect the knock sensor electrical connectors (3).
CAUTION: When separating the catalytic converters from the manifolds, disconnect the oxygen sensor connectors. Allowing the catalytic converters hanging from the oxygen sensor wires damages the harness and/or sensors.
24. Disconnect all oxygen sensor electrical connectors (2).
25. Saturate all exhaust bolts and nuts (3) with Mopar® Rust Penetrant. Allow five minutes for penetration.
26. Remove the both catalytic converter to manifold flange nuts (3) and separate the catalytic converters (4) from the exhaust manifolds.
27. Remove the starter motor (1) heat shield (4).
28. Disconnect the starter wires, remove the starter motor retaining bolts (2) and remove the starter (1). Refer to STARTER, REMOVAL .
29. Remove the CKP sensor electrical connector (1).
30. Remove the generator support bracket to engine mount retaining nut (1).
31. Remove the generator support bracket retaining bolt (2) and remove the support bracket (3).
32. Lower the vehicle.
33. Unsnap the plastic insulator cap from the B+ output terminal.
34. Remove the B+ terminal mounting nut at the rear of the generator and remove the B+ terminal.
35. Depress the field wire connector tab at the rear of the generator and disconnect the field wire connector.
36. Remove the two generator retaining bolts (1) and remove the generator (2).
37. Remove the nut (1) from the front section of the A/C liquid line (2) to the rear section of the liquid line (3), separate the lines, remove and discard the dual plane seal.
38. Install plugs or tape over the opened liquid line fittings.
39. Remove the front section of the A/C liquid line (2) from the engine compartment.
Courtesy of CHRYSLER GROUP, LLC
40. Remove the nut (1) from the front section of the A/C suction line (2) to the rear section of the suction line (3), separate the lines, remove and discard the dual plane seal.
41. Install plugs or tape over the opened suction line fittings.
42. Remove the front section of the A/C suction line (2) from the engine compartment.
43. Remove the oil pressure sensor electrical connector (1).
44. Remove the oil temperature sensor electrical connector.
NOTE:
It is not necessary to disconnect power steering pump hoses from power steering pump for power steering pump removal.
45. Remove the three power steering pump (4) mounting bolts (2) through the access holes in the pulley (3) and position the pump aside.
46. Remove the upper radiator hose clamp (1) and remove the upper radiator hose (2).
47. Remove the oil cooler hose clamp (3) and remove the oil cooler hose (4).
48. Remove the heater tube retaining bolt (1).
49. Remove the coolant temperature sensor electrical connector (2).
50. Lift the heater tube (3) out of the water pump.
51. Disconnect the camshaft position sensor electrical connector (1).
52. Remove the heater hoses (1, 2).
53. Remove the coolant bottle retaining bolts (2) and position the coolant bottle (1) aside.
54. Remove all ignition coil electrical connectors (1) and position the harness aside.
55. Remove the Totally Integrated Power Module (TIPM) and mounting bracket. Refer to MODULE, TOTALLY INTEGRATED POWER (TIPM), REMOVAL .
56. Unfasten the wire harness mounted on the right hand inner fender panel and position aside.
57. Remove the ignition capacitor (1) electrical connector (2).
58. Remove the ground wires from the rear of each cylinder head.
59. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
60. Remove the transmission inspection cover retaining bolt (2) and remove the inspection cover
(1).
61. Manual transmission equipped vehicles, remove the transmission. Refer to REMOVAL .
62. Automatic transmission equipped vehicles, rotate the crankshaft in clockwise direction until the torque converter bolts (1) are accessible and remove the flex plate to torque converter bolts (1).
63. Remove the oil pan to transmission bolts (1).
64. Remove the transmission bell housing to engine block bolts (2).
CAUTION: While carefully separating the engine from the transmission and removing the engine from the vehicle, constant checks must be made to ensure no damage to other components or wiring harnesses occur throughout the removal procedure.
65. Lower the vehicle.
66. Using a suitable jack, support the transmission.
NOTE:
Do not use air tools to install engine lift fixture.
67. Install the (special tool #8984B, Fixture, Engine Lifting) (2) and (special tool #8984-UPD, Adapter, Engine Lift) (4).
68. Using a suitable engine hoist, separate the engine from the transmission and remove the engine from the engine compartment.
69. Secure the engine onto a suitable engine stand.
