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Section 1 (3.6L Engine (Service Information)): Removal: Removal

WARNING: This page is about a different variant/trim than selected.
Fig 1: Removing/Installing Cowl Panel
GC0080264Courtesy of CHRYSLER LLC
  1. Remove the hood. Refer to HOOD , Removal .
  2. Remove the cowl panel cover (2). Refer to COVER, Cowl Panel , Removal .
  3. Remove the strut tower support (6).
    Fig 2: Negative Battery Cable
    GC0139402Courtesy of CHRYSLER LLC
  4. Perform the fuel pressure release procedure. Refer to Fuel Delivery, Gas, Standard Procedure .
  5. Disconnect and isolate the negative battery cable (1).
  6. Perform the Refrigerant System Recovery procedure. Refer to Plumbing , Standard Procedure .
    Fig 3: Engine Cover
    GC0144028Courtesy of CHRYSLER LLC
  7. Lift the engine cover retaining grommets off the ball studs and remove the engine cover (1).
    Fig 4: Air Inlet Hose
    GC0144029Courtesy of CHRYSLER LLC
  8. Disconnect the electrical connector (1) from the Inlet Air Temperature (IAT) sensor.
  9. Loosen the clamp (2) at the throttle body.
  10. Loosen the clamp (3) at the air cleaner housing.
  11. Lift the air inlet hose assembly retaining grommet off the ball stud (4).
  12. Remove the air inlet hose assembly (5).
    Fig 5: Electrical Connector, Air Cleaner Housing & Bolt
    GC0144030Courtesy of CHRYSLER LLC
  13. Disconnect the fresh air makeup hose (1) from the air cleaner housing.
  14. Remove the air cleaner housing retaining bolt (2).
  15. Remove the air cleaner housing (3).
    Fig 6: Lower Splash Shield & Fasteners
    GC0095584Courtesy of CHRYSLER LLC
  16. Raise and support the vehicle. Refer to Hoisting , Standard Procedure .
  17. Remove the belly pan retainers (1) and remove the belly pan.
  18. Drain the cooling system. Refer to Standard Procedure .
  19. Drain the engine oil. Refer to STANDARD PROCEDURE - ENGINE OIL AND FILTER CHANGE .
    Fig 7: Front Axle Removal/Installation
    GC0081412Courtesy of CHRYSLER LLC
  20. If equipped with AWD, remove the front axle assembly (1). Refer to Removal .
    Fig 8: Upstream Oxygen Sensor & Electrical Connector
    GC0144655Courtesy of CHRYSLER LLC
    NOTE:

    Left side shown in illustration, right side similar.

  21. Disconnect both left and right upstream oxygen sensor (2) electrical connectors (1).
    Fig 9: Exhaust Down Pipe & Retaining Nuts
    GC0144658Courtesy of CHRYSLER LLC
    NOTE:

    Left side shown in illustration, right side similar.

  22. Remove the exhaust down pipe (1) to catalytic converter retaining nuts (2) from both left and right down pipes.
    Fig 10: Torque Converter Bolt
    GC0144169Courtesy of CHRYSLER LLC
  23. Remove the starter motor. Refer to STARTER , Removal .
  24. Rotate the crankshaft in a clockwise direction until the torque converter bolts (1) are accessible through the starter mounting hole and remove the six torque converter bolts (1).
  25. Lower the vehicle.
    Fig 11: Coolant Bottle Return Hose
    GC0144662Courtesy of CHRYSLER LLC
  26. Remove the coolant bottle return hose (1).
    Fig 12: Heater Core Purge Hose, Coolant Bottle Retaining Bolts & Coolant Bottle
    GC0144663Courtesy of CHRYSLER LLC
  27. Remove the heater core purge hose (1) from the coolant bottle.
  28. Remove the coolant bottle retaining bolts (2).
  29. Remove the coolant bottle (3).
    Fig 13: EVAP Purge Solenoid, Electrical Connector & Vacuum Lines
    GC0144652Courtesy of CHRYSLER LLC
  30. Disconnect the vacuum line (3) at the EVAP purge solenoid (1).
  31. Disconnect the EVAP purge solenoid vacuum line (4) at the intake manifold and remove the vacuum line.
    Fig 14: PCV Valve, Intake Manifold, Brake Booster Vacuum Hose, MAP Sensor, ETC & CMP Sensor Electrical Connectors
    GC0144654Courtesy of CHRYSLER LLC
  32. Disconnect the PCV hose from the PCV valve (1) and the intake manifold (2) and remove hose.
  33. Disconnect the brake booster vacuum hose (3) and position aside.
  34. Disconnect the electrical connector at the Manifold Absolute Pressure (MAP) Sensor (4).
  35. Disconnect the electrical connector at the Electronic Throttle Control (ETC) (5).
  36. Disconnect the electrical connector at the Camshaft Position Sensor (CMP) (6) and position harness aside.
    Fig 15: Fresh Air Makeup Hose At Rear Of Intake Manifold
    GC0144653Courtesy of CHRYSLER LLC
  37. Remove the fresh air makeup hose (2) from the rear of the intake manifold (1).
    Fig 16: Upper Intake Manifold
    GC0144183Courtesy of CHRYSLER LLC
  38. Remove the upper intake manifold (2) and insulator. Refer to MANIFOLD, Intake , Removal .
    Fig 17: Fuel Supply Hose At Underbody Fuel Supply Tube
    GC0144399Courtesy of CHRYSLER LLC
  39. Disconnect the fuel supply hose (1) from the underbody fuel supply tube (2). Refer to FITTING, Quick Connect , Standard Procedure .
    Fig 18: Cooling Fan Module Components
    GC0144321Courtesy of CHRYSLER LLC
  40. Remove the cooling fan module. Refer to FAN, Cooling , Removal .
    CAUTION:

    Do not let the tensioner arm snap back to the freearm position, sever damage may occur to the tensioner.

    Fig 19: New Belt, Idler Pulley, Tensioner Arm, Belt, Idler & Tensioner
    GC0144013Courtesy of CHRYSLER LLC
  41. Rotate the accessory drive belt tensioner (7) counterclockwise until it contacts the stop and remove the accessory drive belt (3), then slowly rotate the tensioner into the freearm position.
  42. Remove the generator (1). Refer to GENERATOR , Removal .
    Fig 20: Variable Valve Timing Solenoid Connectors & Harness Retainers
    GC0144413Courtesy of CHRYSLER LLC
    NOTE:

    Mark the variable valve timing solenoid connectors (2) with a paint pen or equivalent so that they may be reinstalled in their original locations.

  43. Disconnect the electrical connectors (2) from the variable valve timing solenoids on the right cylinder head.
  44. Unfasten the starter harness to main harness retainer (3).
  45. Unfasten the two starter wire harness retainers (1) from the right cylinder head cover.
    Fig 21: Main Wire Harness Retainer & Connector
    GC0144408Courtesy of CHRYSLER LLC
  46. Unfasten the main wire harness retainer (2) from the right cylinder head cover mounting stud.
    Fig 22: Main Wire Harness Retainers At Right Cylinder Head Cover
    GC0144409Courtesy of CHRYSLER LLC
  47. Unfasten the four main wire harness retainers (1) from the right cylinder head cover.
    Fig 23: Wire Harness Retainers, Oil Pump Solenoid Electrical Connector & Ground Strap
    GC0144414Courtesy of CHRYSLER LLC
  48. Disconnect the oil pump solenoid electrical connector (2).
  49. Unfasten the four wire harness retainers (1).
  50. Remove the ground strap (3) from the right engine mount bracket.
    Fig 24: Variable Valve Timing Solenoid Connectors & Wire Harness Retainers
    GC0144410Courtesy of CHRYSLER LLC
    NOTE:

    Mark the variable valve timing solenoid connectors (2) with a paint pen or equivalent so that they may be reinstalled in their original locations.

  51. Disconnect the electrical connectors (2) from the left variable valve timing solenoids.
  52. Unfasten the two starter wire harness retainers (1) from the left cylinder head cover.
    Fig 25: A/C Compressor Electrical Connector & Wire Harness Retainer
    GC0144411Courtesy of CHRYSLER LLC
  53. Disconnect the A/C compressor electrical connector (1) and unfasten the wire harness retainer (2) from the A/C compressor discharge line.
    Fig 26: Starter Wire Harness Retainers, Main Wire Harness Retainer & Manifold Support Bracket Retainers
    GC0144415Courtesy of CHRYSLER LLC
  54. Unfasten the two starter wire harness retainers (1) from the upper intake manifold support brackets.
  55. Unfasten the main wire harness retainer (3) from the left cylinder head cover and two retainers (2) from the upper intake manifold support brackets.
    Fig 27: ECT Sensor Connector, CMP Sensor & Main Wire Harness Retainers
    GC0144416Courtesy of CHRYSLER LLC
  56. Disconnect the Engine Coolant Temperature (ECT) sensor connector (3).
  57. Disconnect the left Camshaft Position (CMP) sensor (5).
  58. Unfasten the main wire harness retainer (2) from the cylinder head cover and one main wire harness retainer (4) from the cylinder head cover mounting stud.
  59. Unfasten the main wire harness retainer (1) form the rear of the lower intake manifold.
    Fig 28: Upper Radiator Hose
    GC0144173Courtesy of CHRYSLER LLC
  60. Remove the upper radiator hose (1) from the engine thermostat housing.
    Fig 29: Lower Heater Core Return Hose & Lower Radiator Hose
    GC0144660Courtesy of CHRYSLER LLC
  61. Remove the lower heater core return hose (1) from the engine coolant pump housing.
  62. Remove the lower radiator hose (2) from the engine coolant pump housing.
    Fig 30: Heater Core Return Tube Lower Support Bracket Retaining Nut
    GC0144661Courtesy of CHRYSLER LLC
  63. Remove the heater core return tube lower support bracket retaining nut (1).
    Fig 31: Heater Core Return Hose
    GC0144664Courtesy of CHRYSLER LLC
  64. Disconnect the heater core return hose (1).
    Fig 32: Heater Core Return Tube Upper Support Bracket Retaining Nut & Tube
    GC0144665Courtesy of CHRYSLER LLC
  65. Remove the heater core return tube upper support bracket retaining nut (2) and remove tube (1).
    Fig 33: A/C Compressor, Nut, Stud & Three Bolts
    GC0144012Courtesy of CHRYSLER LLC
  66. Remove the A/C compressor (2). Refer to COMPRESSOR, A/C , Removal .
  67. Raise and support the vehicle. Refer to Hoisting , Standard Procedure .
    Fig 34: Wire Harness Retainers
    GC0144417Courtesy of CHRYSLER LLC
  68. Remove the starter. Refer to STARTER , Removal .
  69. Unfasten the starter wire harness retainer (2) and the main wire harness retainer (1) from the engine block.
    Fig 35: Bolt & Transmission Cooling Lines
    GC0144918Courtesy of CHRYSLER LLC
  70. Remove the bolt (1) and reposition the transmission cooling lines (2).
    Fig 36: Heat Shield
    GC0144496Courtesy of CHRYSLER LLC
  71. Push back the heat shield (1) from the crankshaft position (CKP) sensor.
    Fig 37: Main Wire Harness Retainers & CKP Sensor
    GC0144418Courtesy of CHRYSLER LLC
  72. Disconnect the main wire harness from the Crankshaft Position (CKP) sensor (3).
  73. Unfasten the main wire harness retainer (1) from the engine block and one main wire harness retainer (2) from the right engine mount bracket.
  74. Disconnect and reposition the power cord from the engine block heater (if equipped).
    Fig 38: Upper Side Transmission-To-Engine Retaining Bolts
    GC0144667Courtesy of CHRYSLER LLC
  75. Remove the two upper side transmission to engine retaining bolts (1).
    Fig 39: Engine Injection/Ignition Harness & Engine Oil Pressure/Temperature Harness
    GC0144404Courtesy of CHRYSLER LLC
  76. Disconnect the main harness from the engine injection/ignition harness (1) at the rear of the left cylinder head.
  77. Disconnect the main harness from the engine oil pressure/temperature harness (2) at the rear of the left cylinder head.
    Fig 40: Side Engine-To-Transmission Bolt, Transmission Dust Shield Retaining Bolt & Dust Shield
    GC0144170Courtesy of CHRYSLER LLC
  78. Remove the side engine to transmission bolt (1).

    Remove the transmission dust shield retaining bolt (2) and remove the dust shield (3)

    Fig 41: Rubber Plugs
    GC0144915Courtesy of CHRYSLER LLC
  79. Remove the two rubber plugs (1) covering the rear oil seal retainer flange bolts.
    Fig 42: Transmission-To-Engine Oil Pan Bolts
    GC0144171Courtesy of CHRYSLER LLC
  80. Remove four transmission to the engine oil pan bolts (1).
    Fig 43: Heater Core Inlet Tube, Oil Level Indicator & Bolts
    GC0144913Courtesy of CHRYSLER LLC
  81. Lower the vehicle.
  82. Remove two bolts (3) and remove the heater core inlet tube (4).
  83. Remove the bolt (1) and remove the oil level indicator (2).
    Fig 44: Left Intake Manifold Support Brackets & Retaining Bolts
    GC0144406Courtesy of CHRYSLER LLC
  84. Remove the left intake manifold support bracket retaining bolts (2) and remove the support brackets (1).
    Fig 45: Driver Side Engine Lifting Bracket & Bolts
    GC0144309Courtesy of CHRYSLER LLC
  85. Install the Driver Side Engine Lifting Bracket (special tool #10242-1, Brackets, Engine Lifting, Left Side) (1) on the left cylinder head with bolts (2) provided with the Engine Lifting Bracket and tighten bolts to 21 N.m (15 ft. lbs.).
    Fig 46: Passenger Side Engine Lifting Bracket & Bolts
    GC0144310Courtesy of CHRYSLER LLC
  86. Install the Passenger Side Engine Lifting Bracket (special tool #10242-2, Brackets, Engine Lifting, Right Side) (1) on the right cylinder head with bolts (2) provided with the Engine Lifting Bracket and tighten bolts to 21 N.m (15 ft. lbs.).
    Fig 47: Lifting Sling, Engine Lifting Brackets & Engine Hoist
    GC0144311Courtesy of CHRYSLER LLC
  87. Reposition the starter wire harness and the main wire harness to the rear of the engine compartment.
  88. Position a load-leveling lifting sling (2), such as OTC® 4305 Engine Load Leveler or equivalent, between the engine lifting brackets (3) and an engine hoist (1).
  89. Support the transmission with a suitable jack.
    Fig 48: Electrical Connector, Harness Connector, Hose & Vacuum Pump
    GC0144609Courtesy of CHRYSLER LLC
  90. Unfasten the harness retainer (4) from the electric vacuum pump mounting bracket.
  91. Disconnect the electrical connector (1) from the electric vacuum pump (3).
  92. Remove the quick connect vacuum hose (2) from the electric vacuum pump (3).
    Fig 49: Electric Vacuum Pump, Bolts & Studs
    GC0144605Courtesy of CHRYSLER LLC
  93. Remove the two upper transmission to engine retaining bolts (2) and remove the electric vacuum pump (3).
    Fig 50: Engine Mount Heat Shield Retaining Nuts, Lower Mount Retaining Bolts & Heat Shields
    GC0144614Courtesy of CHRYSLER LLC
    NOTE:

    Left engine mount shown in illustration, right engine mount similar.

  94. Remove both left and right engine mount heat shield retaining nuts (3) and remove the heat shields (4).
  95. Remove both left and right engine mount lower retaining bolts (2).
    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.

  96. Carefully remove the engine from the engine compartment.
  97. If required, remove the following components for installation on the replacement engine:
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