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Engine Assembly PHEV: Notes

WARNING: This page is about a different variant/trim than selected.
WARNING:

Before performing any diagnostic or service procedure, you must thoroughly read and follow all applicable high voltage safety procedures. You must perform the high voltage power down procedures.

Loss of Isolation (LOI) must be performed before high voltage power up in cases where service has been performed on a high-voltage component or when diagnosing a LOI condition.

Be sure to use the proper safety equipment when working on any high voltage system or component. Failure to do so may result in serious or fatal injury.

Wait a minimum of two minutes after performing the high voltage battery disconnect procedure before attempting to access the high voltage system. Failure to do so may result in serious or fatal injury.

CAUTION:

Do not allow coolant to come in contact with any high voltage component electrical connections. Engine coolant will create a conductive path and cannot be effectively removed resulting in a loss of isolation and replacement of the contaminated high voltage component.

REMOVAL 

  1. Perform the fuel pressure release procedure. Refer to FUEL SYSTEM PRESSURE RELEASE .
  2. Drain the engine cooling system. Refer to DRAINING .
  3. Drain the low temp cooling system. Refer to DRAINING .
  4. Drain the battery cooling system. Refer to BATTERY COOLING, STANDARD PROCEDURE .
  5. Drain the engine oil. Refer to ENGINE OIL AND FILTER CHANGE .
  6. Remove the support and lower the vehicle.
  7. Recover the A/C system refrigerant. Refer to R-1234YF REFRIGERANT SYSTEM RECOVERY .
  8. Power down the high voltage system. Refer to HIGH VOLTAGE POWER DOWN .
  9. Remove the catalytic converter. Refer to CONVERTER, CATALYTIC, REMOVAL AND INSTALLATION .
  10. Remove the battery skid plate. Refer to PLATE, SKID, REMOVAL AND INSTALLATION .
  11. Remove the top and side engine covers.
  12. Remove the coolant line bracket nut from the top of turbocharger.
  13. Remove the Charge Air Cooler (CAC) inlet tube. Refer to COOLER AND HOSES, CHARGE AIR .
  14. Remove the rear drive shaft. Refer to REAR DRIVESHAFT .
  15. Remove the front drive shaft. Refer to FRONT DRIVESHAFT .
  16. Remove the high voltage wire harness retainers from the transfer case shield bracket.
  17. Remove the bolts and the transfer case shield bracket.
  18. Remove the two transfer case wire harness retainers from the right side of transfer case.
  19. Lower the transmission.
  20. Remove the lower fuel injection pump shield nuts and the fuel injection pump shield.
    GC0207071Courtesy of CHRYSLER GROUP, LLC
    1 - Lower Fuel Injection Pump Shield
    2 - Fuel Injection Pump Shield Isolator Nuts
  21. Remove the bolt securing the coolant tube to the high voltage bracket (right side rear).
  22. Remove the bolts securing the coolant tube to engine block and position aside the coolant tube (right side rear).
  23. Remove the bolts securing the high voltage cable to the transmission (right side).
  24. Remove the high voltage cable retainer from the transmission and position aside the wire harness (right side).
  25. Install the transmission crossmember and securely tighten the bolts.
  26. Remove the jack from under the transmission.
  27. Remove support and lower the vehicle.
  28. Position a jack under the transmission and slightly raise the transmission.
  29. Remove the upper fuel injection pump shield bolt and the fuel injection pump shield.
    GC0207158Courtesy of CHRYSLER GROUP, LLC
    1 - Upper Fuel Injection Pump Shield
    2 - Upper Fuel Injection Pump Shield Bolts
  30. Remove the jack from under the transmission.
  31. Remove the Motor Generator Unit (MGU). Refer to MOTORS, ELECTRIC DRIVE, REMOVAL AND INSTALLATION .
  32. Remove the pressurized coolant bottle. Refer to BOTTLE, COOLANT, REMOVAL AND INSTALLATION .
  33. Remove the low temp pressurized coolant bottle. Refer to BOTTLE, COOLANT, REMOVAL AND INSTALLATION .
  34. Remove the battery pressurized coolant bottle. Refer to RESERVOIR, REMOVAL AND INSTALLATION .
  35. Remove the hood. Refer to HOOD, REMOVAL AND INSTALLATION .
  36. Remove the transmission vent hose retainers and position aside the hose.
  37. Disconnect the fuel pressure sensor wire harness connector.
    GC0207105Courtesy of CHRYSLER GROUP, LLC
    1 - Fuel Pressure Sensor Wire Harness Connector
    2 - Fuel Pressure Sensor
  38. Detach the fuel line retainer.
  39. Remove the fuel line safety lock.
    GC0207021Courtesy of CHRYSLER GROUP, LLC
    1 - Fuel Line Safety Lock
    2 - Fuel Supply Line Quick-Connect Fitting
  40. Disconnect the front fuel supply line quick-connect fitting.
  41. Disconnect the small coolant hose from the top of the coolant manifold.
  42. Disconnect the CAC coolant temperature sensor wire harness connector.
    GC0203164Courtesy of CHRYSLER GROUP, LLC
    1 - Charge Air Cooler Coolant Temperature Sensor Harness Connector
  43. Disconnect the coolant inlet hose quick-connect fitting from the charge air cooler Y-fitting and position aside.
    GC0203517Courtesy of CHRYSLER GROUP, LLC
    1 - Coolant Inlet Hose Quick-Connect Fitting
    2 - Coolant Outlet Hose Quick-Connect Fitting
  44. Remove the nut securing the coolant tube to the bracket.
  45. Disconnect the coolant outlet hose quick-connect fitting from the charge air cooler and position aside.
  46. Disconnect the engine wire harness connector under the PCM.
  47. Detach the two wire harness retainers from body (right side).
  48. Remove the wire harness retainer from the front differential support bracket.
  49. Remove the ground cable bolt and position aside the ground cable. (right side)
    GC0207060Courtesy of CHRYSLER GROUP, LLC
    1 - Ground Cable Bolt
    2 - Ground Cable
  50. Remove the A/C compressor. Refer to COMPRESSOR, A/C, REMOVAL AND INSTALLATION .
  51. Disconnect the lower heater hose.
    GC0203130Courtesy of CHRYSLER GROUP, LLC
    1 - Heater Hose
    2 - Lower Radiator Hose
  52. Disconnect the lower radiator hose.
  53. Remove the intermediate shaft. Refer to SHAFT, INTERMEDIATE, REMOVAL AND INSTALLATION .
  54. Remove the left engine mount heat shield nuts and the heat shield.
    GC0203285Courtesy of CHRYSLER GROUP, LLC
    1 - Heat Shield Nuts
    2 - Heat Shield
  55. Remove the two retainers securing the manual park release cable to the rear of the cylinder head cover (left side).
  56. Remove the left and right half shafts. Refer to REMOVAL AND INSTALLATION .
  57. Detach the transmission wire harness retainers from the bottom of the intake manifold and position aside the wire harness.
  58. Remove the transmission with transfercase. Refer to MPT3015C TRANSFER CASE (ONE SPEED) (SERVICE INFORMATION and/or MPT3028C TRANSFER CASE (SERVICE INFORMATION) .
  59. Remove the bolts securing the A/C lines to the shock tower.
  60. Remove the coolant bottle bracket bolts and the coolant bottle bracket.
    GC0203564Courtesy of CHRYSLER GROUP, LLC
    1 - Coolant Bottle Bracket
    2 - Coolant Bottle Bracket Bolts
  61. Remove the battery chiller. Refer to CHILLER, REMOVAL AND INSTALLATION .
  62. Disconnect the coolant hose on the right shock tower.
  63. Install suitable engine lifting brackets to the engine and position a load-leveling lifting sling between the engine and an engine hoist.
  64. Remove the left lower engine mount bolts.
    GC0203532Courtesy of CHRYSLER GROUP, LLC
    1 - Engine Mount Stud Bolts
    2 - Engine Mount Bolts
    3 - Engine Mount
  65. Remove the right lower engine mount bolts.
    GC0203572Courtesy of CHRYSLER GROUP, LLC
    1 - Engine Mount Stud Bolts
    2 - Engine Mount Bolts
    3 - Engine Mount
  66. Carefully remove the engine from the engine bay.
  67. If required, remove the necessary components for installation onto the replacement engine.

INSTALLATION 

  1. If required, install the necessary components onto the replacement engine.
  2. Install suitable engine lifting brackets to the engine and position a load-leveling lifting sling between the engine and an engine hoist.
  3. Carefully lower the engine into the engine bay.
  4. Install the left lower engine mount bolts and tighten to the proper torque specifications.
    GC0203532Courtesy of CHRYSLER GROUP, LLC
    1 - Engine Mount Stud Bolts
    2 - Engine Mount Bolts
    3 - Engine Mount
  5. Install the right lower engine mount bolts and tighten to the proper torque specifications.
    GC0203572Courtesy of CHRYSLER GROUP, LLC
    1 - Engine Mount Stud Bolts
    2 - Engine Mount Bolts
    3 - Engine Mount
  6. Remove the engine hoist and load-lifting lifting sling from the engine.
  7. Connect the coolant hose on the right shock tower.
  8. Install the battery chiller. Refer to CHILLER, REMOVAL AND INSTALLATION .
  9. Install the coolant bottle bracket and tighten bolts to the proper torque specification.
    GC0203564Courtesy of CHRYSLER GROUP, LLC
    1 - Coolant Bottle Bracket
    2 - Coolant Bottle Bracket Bolts
  10. Install the bolts securing A/C lines to the shock tower and securely tighten.
  11. Install the transmission with transfercase. Refer to REMOVAL AND INSTALLATION .
  12. Position the harness then attach the transmission wire harness retainers to the bottom of the intake manifold.
  13. Install the left and right half shafts. Refer to REMOVAL AND INSTALLATION .
  14. Install the two retainers securing the manual park release cable to the rear of the cylinder head cover (left side).
  15. Install the left engine mount heat shield and tighten the heat shield nuts to the proper torque specifications.
    GC0203285Courtesy of CHRYSLER GROUP, LLC
    1 - Heat Shield Nuts
    2 - Heat Shield
  16. Install the intermediate shaft. Refer to SHAFT, INTERMEDIATE, REMOVAL AND INSTALLATION .
  17. Connect the lower radiator hose.
    GC0203130Courtesy of CHRYSLER GROUP, LLC
    1 - Heater Hose
    2 - Lower Radiator Hose
  18. Connect the lower heater hose.
  19. Install the A/C compressor. Refer to COMPRESSOR, A/C, REMOVAL AND INSTALLATION .
  20. Install the ground cable and tighten bolt to the proper torque specification.
    GC0207060Courtesy of CHRYSLER GROUP, LLC
    1 - Ground Cable Bolt
    2 - Ground Cable
  21. Install the front differential wire harness retainer to the front differential support bracket.
  22. Attach the two wire harness retainers to the body (right side).
  23. Connect the engine wire harness connectors under the PCM.
  24. Connect the coolant outlet hose quick-connect fitting to the charge air cooler.
    GC0203517Courtesy of CHRYSLER GROUP, LLC
    1 - Coolant Inlet Hose Quick-Connect Fitting
    2 - Coolant Outlet Hose Quick-Connect Fitting
  25. Install the nut securing the coolant tube to the bracket and securely tighten.
  26. Connect the coolant inlet hose quick-connect fitting to the charge air cooler Y-fitting.
  27. Connect the CAC coolant temperature sensor wire harness connector.
    GC0203164Courtesy of CHRYSLER GROUP, LLC
    1 - Charge Air Cooler Coolant Temperature Sensor Harness Connector
  28. Connect the small coolant hose to the top of the coolant manifold.
  29. Connect the front fuel supply pipe quick-connect fitting.
    GC0207021Courtesy of CHRYSLER GROUP, LLC
    1 - Fuel Line Safety Lock
    2 - Fuel Supply Line Quick-Connect Fitting
  30. Install the fuel line safety lock.
  31. Attach the fuel line retainer.
  32. Connect the fuel pressure sensor wire harness connector.
    GC0207105Courtesy of CHRYSLER GROUP, LLC
    1 - Fuel Pressure Sensor Wire Harness Connector
    2 - Fuel Pressure Sensor
  33. Install the transmission vent hose retainers
  34. Install the hood. Refer to HOOD, REMOVAL AND INSTALLATION .
  35. Install the battery pressurized coolant bottle. Refer to RESERVOIR, REMOVAL AND INSTALLATION .
  36. Install the low temp pressurized coolant bottle. Refer to BOTTLE, COOLANT, REMOVAL AND INSTALLATION .
  37. Install the pressurized coolant bottle. Refer to BOTTLE, COOLANT, REMOVAL AND INSTALLATION .
  38. Install the Motor Generator Unit (MGU). Refer to MOTORS, ELECTRIC DRIVE, REMOVAL AND INSTALLATION .
  39. Position a jack under the transmission and slightly raise the transmission.
  40. Install the upper fuel injection pump shield and tighten the upper bolts to the proper torque specification.
    GC0207158Courtesy of CHRYSLER GROUP, LLC
    1 - Upper Fuel Injection Pump Shield
    2 - Upper Fuel Injection Pump Shield Bolts
  41. Lower the transmission and remove the jack from under the transmission.
  42. Raise and support the vehicle.
  43. Position a jack under the transmission and raise.
  44. Remove the bolts and the transmission crossmember.
  45. Position the high voltage cable to the transmission and install the wire harness retainer (right side).
  46. Install and securely tighten the bolts securing the high voltage cable to the transmission (right side).
  47. Install and securely tighten the bolts securing the coolant tube to engine block (right side rear).
  48. Install and securely tighten the bolt securing the coolant tube to the high voltage bracket (right side rear).
  49. Install the lower fuel injection pump shield nuts and tighten to the proper torque specifications.
    GC0207071Courtesy of CHRYSLER GROUP, LLC
    1 - Lower Fuel Injection Pump Shield
    2 - Fuel Injection Pump Shield Isolator Nuts
  50. Raise the transmission.
  51. Install the two transfer case wire harness retainers to the right side of transfer case.
  52. Install the transfer case shield bracket and tighten the bolts to the proper torque specifications.
  53. Install the high voltage wire harness retainers to the transfer case shield bracket.
  54. Install the front drive shaft. Refer to REMOVAL AND INSTALLATION .
  55. Install the rear drive shaft. Refer to REMOVAL AND INSTALLATION .
  56. Install the Charge Air Cooler (CAC) inlet tube. Refer to COOLER AND HOSES, CHARGE AIR, REMOVAL AND INSTALLATION .
  57. Install the coolant line bracket nut to the top of the turbocharger and securely tighten.
  58. Install the side and top engine covers.
  59. Install the battery skid plate. Refer to PLATE, SKID, REMOVAL AND INSTALLATION .
  60. Install the catalytic converter. Refer to CONVERTER, CATALYTIC, REMOVAL AND INSTALLATION .
  61. Evacuate and charge the A/C system. Refer to R-1234YF REFRIGERANT SYSTEM EVACUATE and/or R-1234YF REFRIGERANT SYSTEM RECOVERY .
  62. Fill the battery cooling system. Refer to BATTERY COOLING, STANDARD PROCEDURE .
  63. Fill the low temp cooling system. Refer to FILLING THE LOW TEMP COOLING SYSTEM .
  64. Fill the engine cooling system. Refer to FILLING THE HIGH TEMP COOLING SYSTEM .
  65. Install a NEW  oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
  66. Power up the high voltage system. Refer to HIGH VOLTAGE POWER UP .
  67. Start and warm the engine. Check for coolant leaks. Refer to COOLING SYSTEM LEAKS .
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