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3.5L - Service Information: Removal

WARNING: This page is about a different car, the 2006 Dodge Magnum, 2006 Dodge Charger, and 2006 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Radiator Hoses
GC0015396Courtesy of DAIMLERCHRYSLER CORP.
1 - UPPER RADIATOR HOSE
2 - LOWER RADIATOR HOSE
3 - ENGINE OIL COOLER
4 - COOLANT MODULE
NOTE: Capture and store any residual fluid drainage or leakage from ancillary components, in the appropriately marked containers.
  1. Perform the fuel pressure release procedure. Refer to STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE .
  2. Center and secure the steering wheel.
  3. Disconnect negative battery cable.
  4. Evacuate the air conditioning system. (Refer to HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE) .
  5. Remove the hood.
  6. Remove the windshield cowl assembly.
  7. Raise and support the vehicle.
  8. Remove the lower engine close out panel.
  9. Drain the cooling system. (Refer to COOLING - STANDARD PROCEDURE) .
  10. Disconnect the lower radiator hose (2). See Fig 3.
    Fig 2: Front Drive Axle Assembly
    GC0015407Courtesy of DAIMLERCHRYSLER CORP.
    1 - LEFT FRONT DRIVE AXLE
    2 - INTERMEDIATE SHAFT
    3 - OIL PAN
    4 - FRONT DRIVE AXLE HOUSING
  11. Remove the front drive axles and housing (if equipped with AWD). See Fig 2.
    Fig 3: Steering Knuckle
    GC0015397Courtesy of DAIMLERCHRYSLER CORP.
    1 - STEERING COUPLER
    2 - CRADLE
    3 - STEERING GEAR
    4 - BOLT
  12. Disconnect the generator electrical connectors. (Refer to ELECTRICAL/CHARGING/GENERATOR - REMOVAL) .
  13. Separate the steering column coupling (1) from the steering gear (3). See Fig 3.
    Fig 4: Radiator Hoses
    GC0015396Courtesy of DAIMLERCHRYSLER CORP.
    1 - UPPER RADIATOR HOSE
    2 - LOWER RADIATOR HOSE
    3 - ENGINE OIL COOLER
    4 - COOLANT MODULE
  14. Remove the starter and spacer plate. (Refer to ELECTRICAL/STARTING/STARTER MOTOR - REMOVAL) .
  15. Disconnect the oil cooler hose at the oil cooler (3) and remove the cooler hose retainer at the transmission. See Fig 4.
  16. Disconnect the transmission line bracket at the A/C compressor and allow the bolt to rest on the cradle.
    Fig 5: Engine Block Heater
    GC0015398Courtesy of DAIMLERCHRYSLER CORP.
    1 - NEGATIVE BATTERY CABLE
    2 - NEGATIVE BATTERY CABLE
    3 - BLOCK HEATER HARNESS
    4 - ENGINE BLOCK HEATER
  17. Disconnect the ground strap (3) at the right transmission housing. See Fig 5.
  18. Disconnect the engine block heater wiring connector (4) and set aside (if equipped). See Fig 5.
  19. Remove the crankshaft position sensor. (Refer to FUEL SYSTEM/FUEL INJECTION/CRANKSHAFT POSITION SENSOR - REMOVAL) .
    Fig 6: Left Exhaust Pipe To Manifold Union
    GC0015403Courtesy of DAIMLERCHRYSLER CORP.
    1 - HO2S #1
    2 - EXHAUST UNION
    3 - HO2S-#2
  20. Disconnect the left #2 oxygen senor (3) electrical connector and separate the exhaust manifold from the left exhaust pipe (2). See Fig 6.
    Fig 7: Right Exhaust Pipe To Manifold Union
    GC0015402Courtesy of DAIMLERCHRYSLER CORP.
    1 - EXHAUST UNION
    2 - HO2S - #2
  21. Disconnect the right #2 oxygen senor (2) electrical connector and separate the exhaust manifold from the right exhaust pipe (1). See Fig 7.
    Fig 8: Flywheel Bolts
    GC0015406Courtesy of DAIMLERCHRYSLER CORP.
    1 - OIL PAN
    2 - FLYWHEEL
    3 - BOLT
    4 - CRADLE
  22. Remove the flex plate inspection cover and torque converter bolts (3). See Fig 8.
    Fig 9: Transmission Removal
    GC0012851Courtesy of DAIMLERCHRYSLER CORP.
    1 - ENGINE
    2 - BOLTS
    3 - TRANSMISSION
  23. Remove the transmission housing to engine mounting bolts (2) accessible. See Fig 9.
  24. Remove the engine mounting to cradle fasteners.
    Fig 10: Coolant Pipe
    GC0015399Courtesy of DAIMLERCHRYSLER CORP.
    1 - COOLANT PIPE
    2 - HEATER HOSE
    3 - COOLANT RESERVOIR HOSE
  25. Lower the vehicle.
  26. Remove the upper intake manifold. (Refer to ENGINE/MANIFOLDS/INTAKE MANIFOLD - REMOVAL) .
  27. Disconnect the heater hose (2) and coolant reservoir hose (3) from the rear coolant pipe (1). See Fig 10.
    Fig 11: Ignition Coils - Left Cylinder Head
    GC0015401Courtesy of DAIMLERCHRYSLER CORP.
    1 - FUEL RAIL
    2 - IGNITION COILS
    3 - WIRING HARNESS
    4 - LOWER INTAKE MANIFOLD
  28. Disconnect the oxygen sensor connector and the ground wire on the left cylinder head cover.
  29. Disconnect the coolant temperature, cam position, oil pressure sensor electrical connectors.
  30. Disconnect the left ignition coil (2) and fuel injector harness connectors and position the wiring harness (3) aside. See Fig 11.
    Fig 12: Ignition Coils - Right Cylinder Head
    GC0015400Courtesy of DAIMLERCHRYSLER CORP.
    1 - FUEL RAIL
    2 - IGNITION COIL
    3 - CAPACITOR
    4 - ENGINE WIRING HARNESS
  31. Remove the right intake manifold support braces.
  32. Disconnect the capacitor and ground strap from the right cylinder head cover. See Fig 12.
  33. Disconnect the oxygen sensor, knock, EGR, injector and ignition coil harness connectors and position the wiring harness aside. See Fig 12.
  34. Disconnect the engine wiring harness from the transmission housing and remove the remaining transmission housing bolts.
    Fig 13: Engine Lifting Bracket #8534
    GC0015405Courtesy of DAIMLERCHRYSLER CORP.
    1 - LIFTING CHAIN
    2 - ENGINE LIFTING BRACKET # 8534
    3 - CAM POSITION SENSOR
    4 - EGR VALVE
    5 - BOLTS
    6 - COOLANT PIPE
  35. Connect the engine lifting bracket (2) from special tool kit 8534B to the right rear of the cylinder head outer most bolt access hole (5). See Fig 13.
  36. Install a bolt into the inner most bolt access hole (5) next to the engine lift bracket to assure lifting bracket positioning.
    Fig 14: Engine Lifting Point
    GC0015404Courtesy of DAIMLERCHRYSLER CORP.
    1 - LIFTING CHAIN
    2 - UPPER TIMING CHAIN COVER
    3 - POWER STEERING PUMP
    4 - THERMOSTAT HOUSING
  37. Connect a engine hoisting chain (1) to the left timing chain cover (2) engine lifting point and engine lift bracket. See Fig 14.
    CAUTION: While slowly separating the engine from the vehicle, constant checks must be made to assure proper positioning and that no damage to other components or wiring harnesses occur during separation.
    NOTE: As the engine is hoisted from the engine bay area, remove the loosened A/C compressor bolt retaining the transmission cooler lines and direct the lines aside.
  38. Carefully remove the engine from the engine bay area.
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