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Aw60T/6F25 Transaxle

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.

NOTE:

The oil cooler can not be cleaned out. In the event that the engine requires rebuilding or replacement, replace the oil cooler. Refer to COOLER, OIL, REMOVAL .

  1. Remove the engine cover.
  2. Perform the fuel pressure release procedure. Refer to FUEL DELIVERY, STANDARD PROCEDURE .
  3. Recover the refrigerant from the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE .
  4. Disconnect and remove the battery. Refer to BATTERY, REMOVAL .
    Fig 1: Battery Tray & Bolts
    GC0159139Courtesy of CHRYSLER GROUP, LLC
  5. Remove the battery tray assembly. Refer to TRAY, BATTERY, REMOVAL .
  6. Remove the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL .
    Fig 2: PCV Hose, Vent Hose, Oil Separator Housing & Bolts
    GC0155887Courtesy of CHRYSLER GROUP, LLC
  7. Disconnect the PCV hose (1) from the intake manifold and set aside.
  8. Disconnect the vent hose (3) from the cylinder head cover.
  9. Remove the three bolts (2) and remove the oil separator housing (4) from the cylinder head cover.
    CAUTION:

    When servicing components near the vacuum pump, avoid contact with the plastic nipple that connects the vacuum pump to the brake booster hose. It is possible to crack the plastic nipple resulting in a brake booster vacuum leak.

  10. Disconnect the vacuum hose at the brake booster.
  11. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
  12. Remove the belly pan. Refer to BELLY PAN, REMOVAL .
  13. Remove the left and right front wheels.
  14. Remove the front fascia. Refer to FASCIA, FRONT, REMOVAL .
  15. Drain the cooling system. Refer to STANDARD PROCEDURE .
    Fig 3: A/C Lines & Brackets
    GC0158585Courtesy of CHRYSLER GROUP, LLC
  16. Remove the two air conditioning line bracket nuts (1).
    Fig 4: A/C Liquid Line, A/C Discharge Line, A/C Condenser Tapping Block & Bolt
    GC0152540Courtesy of CHRYSLER GROUP, LLC
  17. Remove the bolt (4) and disconnect the A/C liquid line and the A/C discharge line from the A/C condenser tapping block (3). Remove and discard the dual plain seals.
  18. Install plugs in, or tape over, the opened refrigerant line fittings and condenser ports.
    Fig 5: Upper & Lower Bumper Reinforcement
    GC0153091Courtesy of CHRYSLER GROUP, LLC
  19. Remove the fasteners securing the upper bumper reinforcement (1) to the frame/front end module. Repeat on the opposite side and remove the upper bumper reinforcement.
  20. Remove the two screws that secure the cooling module front shroud.
  21. Pinch the upper tabs and set the shroud aside.
    Fig 6: CAC Outlet Hose Quick Connect
    GC0158916Courtesy of CHRYSLER GROUP, LLC
  22. Lift the retainer clip (1) at the charge air cooler (CAC) outlet quick connect. Disconnect the CAC outlet hose (2) from the CAC outlet (3).
    Fig 7: CAC Inlet Hose Quick Connect
    GC0159078Courtesy of CHRYSLER GROUP, LLC
  23. Disconnect the charge air cooler (CAC) inlet hose quick connect (1).
    Fig 8: Bypass Hose & Retainers
    GC0158757Courtesy of CHRYSLER GROUP, LLC
  24. Unlock the bypass hose retainers (1) and set the hose (2) to the side.
  25. Remove the engine ground from the bulkhead to cylinder head.
  26. Remove the air-conditioning line support bracket at the compressor.
  27. Remove the air-conditioning lines from the compressor.
  28. Install plugs in, or tape over, the opened refrigerant line fittings and the compressor ports.
  29. Unplug the auxiliary water pump connector and remove the pump from its mount.
    Fig 9: PCM Electrical Connectors
    GC0152393Courtesy of CHRYSLER GROUP, LLC
  30. Unlock and disconnect the PCM connectors (1 and 2).
  31. Disconnect the heater core inlet and outlet hoses at the quick connects.
    Fig 10: EVAP And Fuel Line Retainer & Locks
    GC0158852Courtesy of CHRYSLER GROUP, LLC
  32. Unlock the evap and fuel line retainer (1) by using a flat blade screwdriver or similar, push down and twist in one motion at the locks (2 and 3).
    Fig 11: Bracket, Gearshift Cable, Manual Valve Lever & TCM Wire Harness Connector
    GC0168972Courtesy of CHRYSLER GROUP, LLC
  33. Disconnect the wire harness connector (4) from the Transmission Control Module (TCM).
  34. Disconnect the gearshift cable (2) from the transmission manual valve lever (3).
  35. Remove the gearshift cable (2) from the bracket (1).
    Fig 12: Bolt & Ground Strap
    GC0168960Courtesy of CHRYSLER GROUP, LLC
  36. Remove the bolt (2) and the ground strap (1) from the transmission.
    Fig 13: Charge Air Cooler Hose, Inlet Quick Connect, Bolt & Clamp
    GC0155791Courtesy of CHRYSLER GROUP, LLC
  37. Disconnect the boost pressure sensor connector from the throttle body inlet pipe.
  38. Loosen the CAC hose clamp (1).
  39. Remove the CAC support fastener (3).
  40. Remove the CAC pipe and hose (2).
    Fig 14: Vacuum Pump Bracket Fasteners & Coolant Hose Retainer
    GC0158884Courtesy of CHRYSLER GROUP, LLC
  41. Disengage the electrical connector retainer and open the coolant hose retainer (2).
  42. Remove the vacuum pump bracket fasteners (1).
  43. Remove the vacuum pump bracket.
    Fig 15: Vacuum Pump & Bolts
    GC0152461Courtesy of CHRYSLER GROUP, LLC
  44. Remove the vacuum line from the vacuum pump (1).
  45. Remove the vacuum pump bolts (2) and remove the vacuum pump.
    Fig 16: Engine Lifting Bracket & Bolts
    GC0152654Courtesy of CHRYSLER GROUP, LLC
  46. Install the (special tool #10299, Bracket, Engine Lifting) (1) on the vacuum pump mounting surface with three bolts (2) provided with the engine lifting bracket. Tighten the bolts to 20 N.m (15 ft. lbs.).
    Fig 17: Coolant Bottle & Bolts
    GC0158996Courtesy of CHRYSLER GROUP, LLC
  47. Disconnect the upper and lower radiator hose quick connects.
  48. Remove the coolant bottle fasteners (2) and set the bottle (1) aside.
    Fig 18: Engine Cooling Radiator Components
    GC0158908Courtesy of CHRYSLER GROUP, LLC
  49. Disconnect the cooling fan motor harness connector (6).
  50. Disconnect the cooling fan resistor harness connector (1).
  51. Release the coolant bottle hose clips (2) to allow the hose to be moved away from the fan module.
  52. Remove the cooling fan module (5). Refer to FAN, COOLING, REMOVAL .
  53. Disconnect the afterrun pump connector and remove the pump from its mount.
    Fig 19: Catalytic Converter, Support Mount & Bolts
    GC0153601Courtesy of CHRYSLER GROUP, LLC
  54. Remove the exhaust pipe from the catalytic converter outlet.
  55. Remove the exhaust flange nuts and the flange gasket.
    Fig 20: Downstream & Upstream Oxygen Sensors With Retainer
    GC0155869Courtesy of CHRYSLER GROUP, LLC
  56. Disconnect the wire harness connectors from the upstream (1) and downstream (2) oxygen sensors.
  57. Disengage the oxygen sensor wire harness from the retainer (3).
  58. Disconnect the horns.
  59. Remove the left and right headlamp assemblies.
    Fig 21: Front Impact Sensor & Connector
    GC0153793Courtesy of CHRYSLER GROUP, LLC
  60. Disconnect the left and right impact sensors (1).
  61. Disengage the hood latch cable from the latch assembly.
    Fig 22: FEM Lower Mounts, Front End Module & Nut
    GC0158889Courtesy of CHRYSLER GROUP, LLC
  62. With assistance of a helper, support the front end module (FEM). Remove the lower bolts (2) from the FEM left and right lower mounts (1). Leave the nut (3) attached to the bumper support (1).
  63. Remove the left and right axle shafts. Refer to REMOVAL .
  64. Remove the intermediate shaft.
  65. Disconnect the lower coolant hose from the radiator.
  66. Remove the rear engine mount. Refer to INSULATOR, ENGINE MOUNT, REAR, REMOVAL .
  67. Lower the vehicle.
  68. Reposition the main wire harness away from the engine.
    Fig 23: Engine Hoist & Load-Leveling Lifting Sling
    GC0152420Courtesy of CHRYSLER GROUP, LLC
  69. Install the engine leveling/lifting device (2). Position an appropriate lifting tool (1) to the leveler.
  70. Lift the engine enough to safely unbolt the transmission and engine mounts.
  71. Remove the left engine mount. Refer to INSULATOR, ENGINE MOUNT, LEFT, REMOVAL .
  72. Remove the right engine mount. Refer to INSULATOR, ENGINE MOUNT, RIGHT, REMOVAL .
  73. Lift the engine and transmission assembly from the vehicle.
    NOTE:

    Make sure the air-conditioning lines are free of the moving components so they are not caught when lifting.

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