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Home >> Chrysler >> 2006 >> PT Cruiser Base, 2D Convertible, Standard >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> 2.4L DOHC Engine >> 2.4L DOHC >> Removal >> Removal - Engine Assembly

Removal - Engine Assembly

Fig 1: Air Inlet System - 2.4L Turbo
GC0042734Courtesy of DAIMLERCHRYSLER CORP.
1 - CLEAN AIR HOSE
2 - AIR CLEANER HOUSING
3 - FRESH AIR INLET DUCT
4 - PDC MOUNTING BRACKET
  1. Perform fuel pressure release procedure, then disconnect and remove fuel line (Refer to FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE) .
  2. Remove air cleaner housing assembly (2) and clean air hose (1), (Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - REMOVAL) .
    Fig 2: Battery Tray Removal/Installation
    GC0021163Courtesy of DAIMLERCHRYSLER CORP.
    1 - BATTERY TRAY
  3. Disconnect both cables from battery.
  4. Remove battery and battery tray (1), (Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - REMOVAL) .
  5. Disconnect battery temperature sensor.
    Fig 3: DRAIN COCK
    GC0042739Courtesy of DAIMLERCHRYSLER CORP.
  6. Drain cooling system, (Refer to DRAINING COOLING SYSTEM - 2.0/2.4L ).
  7. Discharge air conditioning system, if equipped, (Refer to the appropriate procedures under PLUMBING - STANDARD PROCEDURE ).
    Fig 4: THROTTLE CABLE COVER, AIR CLEANER & BATTERY
    GC0042735Courtesy of DAIMLERCHRYSLER CORP.
  8. Remove throttle cable cover.
  9. Disconnect throttle and speed control cables from throttle body.
  10. Disconnect engine wiring harness at Powertrain Control Module (PCM).
    Fig 5: PDC Bracket Attaching Bolts
    GC0021164Courtesy of DAIMLERCHRYSLER CORP.
    1 - PDC
    2 - PDC BRACKET BOLTS
    3 - BATTERY TRAY BOLT
  11. Disconnect positive cable from Power Distribution Center (PDC) (1) and ground wire from vehicle body. Remove bolts attaching PDC (2) and set aside. See Fig 5.
  12. Disconnect wiring connectors at lower battery tray support.
    Fig 6: HEAD GROUND
    GC0042742Courtesy of DAIMLERCHRYSLER CORP.
  13. Disconnect ground wire (1) from the vehicle body-to-engine at the right side strut tower.
  14. Disconnect brake booster vacuum hose from intake manifold.
  15. Disconnect the proportional purge hose from throttle body.
  16. Disconnect coolant reserve/recovery hose from coolant outlet connector.
  17. Disconnect heater hoses.
    Fig 7: GRILL REMOVAL
    GC0042741Courtesy of DAIMLERCHRYSLER CORP.
  18. Remove grill (2) (Refer to BODY/EXTERIOR/GRILLE - REMOVAL) .
    Fig 8: Upper Radiator Closure Panel And Center Brace
    GC0019362Courtesy of DAIMLERCHRYSLER CORP.
    1 - UPPER RADIATOR CLOSURE PANEL
    2 - CENTER BRACE
  19. Remove upper radiator closure (1) and center brace (2) (Refer to BODY/EXTERIOR/RADIATOR CROSSMEMBER - REMOVAL) . See Fig 8.
  20. Remove upper radiator hose.
  21. Remove lower radiator hose.
  22. Remove thermostat housing.
    Fig 9: A/C LINES
    GC0042736Courtesy of DAIMLERCHRYSLER CORP.
  23. Disconnect upper A/C line from A/C condenser.
  24. Disconnect A/C lines at junction near upper torque strut.
  25. Automatic Transmission equipped vehicles: 
    • Using a blade or suitable hose cutter, cut transaxle oil cooler lines off flush with transmission fittings. Plug lines and fittings to prevent debris from entering transaxle or cooler circuit. A service splice kit will be installed upon reassembly.
    • Disconnect transmission electrical connectors.
    • Disconnect transmission shift linkage.
    Fig 10: Disconnect Clutch Hydraulic Quick Connect Fittiing Using Tool 6638A
    GC0020073Courtesy of DAIMLERCHRYSLER CORP.
    1 - QUICK CONNECT FITTING
    2 - DISCONNECT TOOL 6638 A
  26. Manual Transmission equipped vehicles: 
    • Using Special Tool 6638A (2), disconnect clutch hydraulic line. See Fig 10.
    • Disconnect transmission shift linkage.
    • Disconnect transmission electrical connectors.
  27. Turbocharger equipped vehicles:   Disconnect power steering hoses from radiator.
  28. Disconnect radiator fan electrical connector and remove cooling module assembly (fan, radiator, A/C condenser, transmission oil cooler).
  29. Hoist vehicle and remove front wheels.
  30. Remove right and left inner splash shields.
  31. Remove both axle shafts (Refer to DIFFERENTIAL & DRIVELINE/HALF SHAFT - REMOVAL) .
  32. Remove accessory drive belts (Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL) .
  33. Remove generator and support brackets.
    Fig 11: Charge Air Cooler Hoses
    GC0019344Courtesy of DAIMLERCHRYSLER CORP.
    1 - HOSE - CHARGE AIR COOLER TO THROTTLE BODY
    2 - CHARGE AIR COOLER
    3 - HOSE - TURBOCHARGER TO CHARGE AIR COOLER
  34. Turbocharger equipped vehicles:   Remove charge air cooler hoses (1 & 3). See Fig 11.
  35. Drain engine oil.
    Fig 12: Converter to Exhaust Manifold Connection - 2.4L Turbo
    GC0019346Courtesy of DAIMLERCHRYSLER CORP.
    1 - FLAG NUT
    2 - GASKET
    3 - NUT
    4 - BOLT
    5 - CATALYTIC CONVERTER
  36. Disconnect the downstream oxygen sensor connector.
  37. Disconnect exhaust system from manifold (1). See Fig 12.
    Fig 13: Power Steering Fluid Pressure Hose
    GC0021166Courtesy of DAIMLERCHRYSLER CORP.
    1 - STEERING GEAR
    2 - FITTING
    3 - POWER STEERING PRESSURE HOSE
  38. Non-Turbo equipped vehicles:   Disconnect power steering pressure hose (3) from steering gear (1). See Fig 13.
    Fig 14: Hoses At Power Steering Gear - 2.4L Turbo
    GC0021171Courtesy of DAIMLERCHRYSLER CORP.
    1 - POWER STEERING GEAR
    2 - ROUTING CLIP
    3 - PRESSURE HOSE TUBE NUT
    4 - RETURN HOSE CLAMP
    5 - PRESSURE/RETURN HOSE ASSEMBLY
  39. Turbocharger equipped vehicles:   Disconnect both power steering hoses (3 & 5) from steering gear (1). See Fig 14.
    Fig 15: Turbocharger Brackets And Heat Shields
    GC0019350Courtesy of DAIMLERCHRYSLER CORP.
    1 - UPPER/LOWER HEAT SHIELDS
    2 - TURBOCHARGER SUPPORT BRACKET
    3 - ELBOW
    4 - ELBOW SUPPORT BRACKET
  40. Turbocharger equipped vehicles:   Remove upper and lower heat shields (1), elbow support bracket (4), turbocharger support bracket (2), and elbow (3). See Fig 15.
  41. Remove structural collar (Refer to ENGINE/ENGINE BLOCK/STRUCTURAL COLLAR - REMOVAL) .
  42. Automatic Transmission equipped vehicles: 
    • Remove torque converter bolts and mark converter to flex plate orientation for reassembly.
  43. Manual Transmission equipped vehicles: 
    • Remove drive plate to clutch module bolts and mark plate orientation for reassembly.
    Fig 16: View Of Pencil Strut Mounting
    GC0042746Courtesy of DAIMLERCHRYSLER CORP.
    1 - NUT
    2 - PENCIL STRUT
    3 - NUT
    4 - FLAT WASHER
    5 - LOWER TORQUE STRUT
  44. Remove lower engine torque strut (5) (Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - REMOVAL) .
  45. Lower vehicle and remove A/C compressor.
  46. Disconnect power steering lines from power steering pump.
  47. Remove power steering pump.
    Fig 17: Positioning Engine Cradle Support Post
    GC0021170Courtesy of DAIMLERCHRYSLER CORP.
    1 - POST LOCATING HOLES IN BLOCK
    2 - POST POSITIONED UNDER BRACKET
    3 - POST LOCATING HOLE IN STRUT
    4 - SAFETY STRAPS
    5 - FLOOR JACK
    6 - POST KIT ENGINE CRADLE 6848
    7 - DOLLY 6135
    8 - CRADLE 6710
  48. Raise vehicle enough to allow engine dolly (7), cradle (8), and posts (6), to be installed under vehicle. For Special Tool identification (Refer to ENGINE - SPECIAL TOOLS) .
  49. Loosen engine support posts (6) to allow movement for positioning onto engine locating holes and flange on the engine bedplate. Lower vehicle and position cradle (8) until the engine is resting on support posts (6). See Fig 17. Tighten mounts to cradle (8) frame. This will keep support posts (6) from moving when removing or installing engine and transmission.
  50. Install safety straps (4) around the engine to cradle (8). See Fig 17. Tighten safety straps (4) and lock them into position.
    WARNING: Safety straps MUST be used.
  51. Raise vehicle enough to determine if safety straps (4) are secure enough to hold cradle (8) assembly to engine.
  52. Lower vehicle so weight of the engine and transmission ONLY is on the cradle (8) assembly.
    Fig 18: Right Mount Through Bolt
    GC0021168Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOLT
    2 - RIGHT ENGINE MOUNT
    3 - ENGINE MOUNT BRACKET
  53. Remove the upper engine torque strut.
  54. Remove right mount through bolt (1). See Fig 18.
    Fig 19: Left Mount & Bolt
    GC0021169Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOLT
    2 - TRANSAXLE
    3 - LEFT MOUNT
  55. Remove left mount (3) attaching bolts. See Fig 19.
  56. Raise vehicle slowly until engine/transaxle assembly clears engine compartment. It may be necessary to move the engine/transmission assembly with the cradle to allow for removal around body flanges.
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