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Section 2 (3.2L Engine (Service Information)): Removal

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

GC0159742Courtesy of CHRYSLER GROUP, LLC
  1. Remove the engine cover (1) from the mounting posts (2).
  2. Perform the fuel system pressure release procedure. Refer to FUEL SYSTEM PRESSURE RELEASE .
  3. Remove the battery. Refer to BATTERY, REMOVAL .
    GC0159542Courtesy of CHRYSLER GROUP, LLC
  4. Remove the pinch bolt (3) from the intermediate shaft (1).
  5. Separate the intermediate shaft from the steering gear shaft (2).
    GC0160052Courtesy of CHRYSLER GROUP, LLC
  6. Remove the cover from the Power Distribution Center (PDC).
  7. Remove the nuts (2) from Z case fuse array and move the eyelet connectors off and away from the Z case fuse array.
    GC0159813Courtesy of CHRYSLER GROUP, LLC
  8. Remove the bolt (2) that secures the engine harness connector to the PDC (1).
  9. Release the plastic clips that secure the PDC to the lower cover.
  10. Using care, lift the PDC away from the lower cover.
  11. Separate the engine harness from the base of the PDC and position aside.
    GC0159262Courtesy of CHRYSLER GROUP, LLC
  12. Disconnect the Powertrain Control Module (PCM) harness connectors (2).
  13. Remove the nut (3) that secures the ground strap (4) to the PCM.
  14. Recover the refrigerant from the A/C system. Refer to PLUMBING, STANDARD PROCEDURE .
  15. Remove the purge control solenoid from the intake manifold. Refer to SOLENOID, EVAPORATIVE EMISSIONS PURGE, REMOVAL .
    GC0160019Courtesy of CHRYSLER GROUP, LLC
  16. Remove the nut (3) and separate the suction/liquid line manifold (2) from the Internal Heat Exchanger (IHX) (1).
  17. Remove the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL .
  18. Remove the air cleaner resonator. Refer to RESONATOR, AIR CLEANER, REMOVAL .
    NOTE:

    Removal of the Intake Resonator will allow access to the rear O2 Sensors and the upper Catalytic Converter bolts.

    GC0159493Courtesy of CHRYSLER GROUP, LLC
  19. Disconnect both right side (rear) O2 Sensor harness connectors (1, 2).
    NOTE:

    The catalytic converter is removed from under the vehicle.

    GC0160133Courtesy of CHRYSLER GROUP, LLC
  20. Remove the right side (rear) catalytic converter support bracket bolt (4).
  21. Remove the catalytic converter upper flange bolts (5).
    GC0159227Courtesy of CHRYSLER GROUP, LLC
  22. If equipped, separate the block heater electrical cord clip (1) from the battery tray.
  23. Separate the engine wiring harness retainer (3) from the battery tray.
  24. Separate the engine harness connector (2) from the battery tray.
    GC0159552Courtesy of CHRYSLER GROUP, LLC
  25. Disconnect the engine side harness connector (4) from the body side harness connector (1).
    GC0159788Courtesy of CHRYSLER GROUP, LLC
  26. Remove the upper battery tray bolts (1, 2).
  27. Raise and support the vehicle.
  28. Remove the belly pan (3). Refer to BELLY PAN, REMOVAL .
  29. Drain the cooling system. Refer to DRAINING .
  30. Partially lower the vehicle.
  31. Remove the front bumper fascia. Refer to FASCIA, FRONT, REMOVAL .
  32. Remove the pressurized coolant bottle supply tube.
  33. Remove both front wheel assemblies. Refer to REMOVAL .
  34. Remove both axleshafts. Refer to REMOVAL .
  35. Remove both front wheel house splash shields. Refer to REMOVAL .
    GC0158453Courtesy of CHRYSLER GROUP, LLC
  36. Remove the heater hose (1) from the water pump.
  37. Remove the lower radiator hose (2) from the water pump.
    GC0160008Courtesy of CHRYSLER GROUP, LLC
  38. Separate the wiring harness retainer (1) from the battery tray.
  39. Remove the bolt (2) that secures the washer reservoir bottle to the battery tray.
    GC0159475Courtesy of CHRYSLER GROUP, LLC
  40. Remove the outer battery tray bolt (2).
  41. Raise and secure the vehicle.
  42. Remove the exhaust crossunder pipe. Refer to 3.2L .
    GC0160127Courtesy of CHRYSLER GROUP, LLC
  43. Separate the Y-pipe (4) from the rear catalytic converter.
    GC0159750Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    FWD  intermediate shaft bracket shown in illustration. AWD  intermediate shaft bracket similar.

  44. If equipped, remove the Power Transfer Unit (PTU). Refer to REMOVAL .
  45. Remove the catalytic converter from its mount and position aside.
  46. Remove the bolts (2, 3) that secure the intermediate shaft support bracket (1).
  47. Remove the rear catalytic converter from the vehicle.
    NOTE:

    If the transmission is to be separated from the engine, removal of the torque converter bolts and lower transmission mounting bolts are best accomplished at this time.

    GC0159205Courtesy of CHRYSLER GROUP, LLC
  48. Remove the bolt (2) that secures the ground wire (1) to the transmission.
    GC0159240Courtesy of CHRYSLER GROUP, LLC
  49. If required, remove the transaxle torque converter housing dust cover (2) and the lower rubber plugs.
    GC0160135Courtesy of CHRYSLER GROUP, LLC
  50. If required, remove the torque converter-to-flexplate bolts (1).
  51. If required, remove the lower engine oil pan-to-transmission bolts.
    GC0159945Courtesy of CHRYSLER GROUP, LLC
  52. Disconnect the oil cooler lines (1) from transmission using the (special tool #9546, Disconnect Tool).
  53. Remove the front suspension crossmember. Refer to REMOVAL .
    GC0160024Courtesy of CHRYSLER GROUP, LLC
  54. Remove the lower bolts (3) that secure the battery tray (1) to the upper frame (2).
  55. Lower the vehicle.
  56. Remove the battery tray from the vehicle.
  57. If required, remove the electric vacuum pump and mounting bracket. Refer to REMOVAL 3.2L .
    GC0156343Courtesy of CHRYSLER GROUP, LLC
  58. Disconnect the heater core supply hose (2).
  59. Disconnect the heater core return hose (3).
    GC0159619Courtesy of CHRYSLER GROUP, LLC
  60. Separate the upper radiator hose (2) from the radiator inlet pipe (1).
    GC0159818Courtesy of CHRYSLER GROUP, LLC
  61. Remove the nuts that secure the A/C lines (1) to the IHX.
    GC0160099Courtesy of CHRYSLER GROUP, LLC
  62. Disconnect the shift cable end from the manual valve lever on the transmission.
  63. Release the locks holding the shift cable housing (2) to the mount bracket (1) on the transmission.
  64. Separate the shift cable from the mount bracket.
  65. Disconnect the fuel line from the fuel rail inlet. Refer to FUEL SYSTEM/FUEL DELIVERY/FITTING, QUICK CONNECT - STANDARD PROCEDURE .
    GC0159634Courtesy of CHRYSLER GROUP, LLC
  66. Remove the nut (2) that secures the ground wire (1) to the right side upper frame (3).
    GC0147013Courtesy of CHRYSLER GROUP, LLC
  67. Raise and position vehicle height to allow the Dolly, Power Train (special tool #6135, Dolly, Power Train) (3) and the Cradle, Engine Support (special tool #6710A, Cradle, Engine Support) (2) to be installed under the engine/transmission assembly.
  68. Loosen the cradle assembly from the power train dolly to allow for adjustment.
  69. Position the Adapter (special tool #6848-3, Adapter) to the engine locating holes (1) on the engine block and oil pan rail.
  70. Lower the vehicle and position the cradle/dolly fixture until the engine is resting on the adapters.
  71. Tighten the engine cradle adapter to the cradle frame.
  72. Secure the engine/transmission assembly to the dolly/cradle with safety straps (4).
  73. Using care, lower the vehicle so that all of the weight of the engine and transmission is on the cradle/dolly fixture.
    GC0159450Courtesy of CHRYSLER GROUP, LLC
  74. Remove the bolts (1) that secure the left engine mount to transmission mount bracket.
    GC0158452Courtesy of CHRYSLER GROUP, LLC
  75. Remove the bolts (2, 3) that secure the right engine mount to engine mount bracket.
  76. Slowly raise the vehicle in small increments while inspecting each interval for potential engine or transmission contact to vehicle components.
  77. Move the cradle/dolly fixture as necessary to allow for removal clearance.
    NOTE:

    Perform the following steps to remove the transmission from the engine if required.

  78. Position and secure a transmission jack under the transmission.
  79. Remove the starter. Refer to 3.2L .
    GC0159235Courtesy of CHRYSLER GROUP, LLC
  80. Rotate the lock lever (1) counterclockwise on the transmission harness connector.
  81. Separate the transmission harness connector from the transmission.
    GC0159743Courtesy of CHRYSLER GROUP, LLC
  82. Remove the remaining transmission upper bellhousing-to-block bolts (3).
  83. Separate the transmission (4) and the spacer plate (2) from the engine.
  84. Remove the bolts that secure the driveplate (1) to the crankshaft.
    NOTE:

    Perform the following steps to remove the engine from the cradle/dolly fixture if required.

    GC0159756Courtesy of CHRYSLER GROUP, LLC
  85. If required, remove all the necessary components from the engine.
  86. Position an engine hoist to the engine assembly (1).
  87. Affix a chain to the engine.
  88. Using care, separate the engine from the cradle/dolly fixture (2, 3).
  89. Secure the engine to a engine stand.
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