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Section 4 (2.0L Engine (Service Information)): Removal

WARNING: This page is about a different variant/trim than selected.
  1. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
  2. Perform the Fuel System Pressure Release procedure

    Refer to FUEL SYSTEM PRESSURE RELEASE .

  3. Disconnect and isolate the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), disconnect the IBS connector first before disconnecting the negative battery cable.
  4. Using a steering wheel holder, lock the steering wheel in place to keep it from rotating. This keeps the clockspring in the proper orientation.
    GC0159542Courtesy of CHRYSLER GROUP, LLC
  5. Remove intermediate shaft pinch bolt (3) and separate the intermediate shaft (1) from the steering gear pinion shaft (2). DISCARD the pinch bolt (3), it is not to be reused.
  6. Drain the cooling system. Refer to DRAINING .
  7. If required, drain the engine oil. Refer to ENGINE/LUBRICATION/OIL - STANDARD PROCEDURE .
  8. Recover the refrigerant from the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE .
  9. Remove the top engine cover. Refer to COVER, ENGINE, REMOVAL .
  10. Remove the battery. Refer to BATTERY, REMOVAL .
  11. Remove the Powertrain Control Module (PCM) and the PCM mount. Refer to MODULE, POWERTRAIN CONTROL (PCM), REMOVAL .
  12. Remove the Power Distribution Center (PDC). Refer to CENTER, POWER DISTRIBUTION (PDC), REMOVAL .
  13. Disengage the wire harness retainers from the battery tray.
  14. Remove the clean air hose. Refer to REMOVAL  .
  15. Remove the air cleaner body. Refer to REMOVAL  .
    GC0186391Courtesy of CHRYSLER GROUP, LLC
  16. Disconnect the fuel supply hose quick connect fitting (2) and separate the fuel lines.
    GC0183549Courtesy of CHRYSLER GROUP, LLC
  17. Disconnect the quick connect fitting and remove the fuel vapor supply pipe from the purge solenoid (2).
  18. Remove the catalytic converter. Refer to CONVERTER, CATALYTIC, REMOVAL .
    GC0187026Courtesy of CHRYSLER GROUP, LLC
  19. Disconnect the heater core supply (2) and return (1) hoses at the quick-connect couplings.
    GC0159257Courtesy of CHRYSLER GROUP, LLC
  20. Release the lock on the Transmission Control Module (TCM) wire harness connector (1).
  21. Disconnect the TCM wire harness connector (1) from the TCM.
    GC0162323Courtesy of CHRYSLER GROUP, LLC
  22. Remove the nut (1) holding the wiring harness bracket and the nut (2) holding the ground cable to the top of the transmission.
  23. Separate the ground cable and the wiring harness bracket from the top of the transmission and position aside.
    GC0162199Courtesy of CHRYSLER GROUP, LLC
  24. Detach the four (2 shown in illustration) wiring harness push pins (1) from the top of the transmission.
    GC0186564Courtesy of CHRYSLER GROUP, LLC
  25. Loosen the band clamp and remove the coolant reservoir supply hose (1) from the turbocharger coolant return pipe.
  26. Loosen the band clamp and remove the charge air cooler hose (2) from the turbocharger coolant return pipe.
    GC0186887Courtesy of CHRYSLER GROUP, LLC
  27. Loosen the band clamp and remove the upper radiator hose (1) from the thermostat housing (2).
    GC0186399Courtesy of CHRYSLER GROUP, LLC
  28. Loosen the band clamp and remove the lower radiator hose (1) from the water pump inlet tube.
  29. Remove the pressurized coolant bottle. Refer to REMOVAL .
    GC0186611Courtesy of CHRYSLER GROUP, LLC
  30. Remove the two nuts (1) and the A/C discharge and suction lines (2) from the A/C compressor.
  31. Remove and discard the O-ring seals.
  32. Install tape or plugs into the opened refrigerant line fittings and the compressor ports.
    GC0159945Courtesy of CHRYSLER GROUP, LLC
  33. Disengage the quick couplings and remove the cooler lines (1) from the transmission. If accessible, install suitable cap-plugs in the male and female ends of the cooler lines to prevent leakage.
  34. Remove both front tire and wheel assemblies and the front wheelhouse inner splash shields. Refer to REMOVAL .
  35. Remove the front fascia assembly. Refer to FASCIA, FRONT, REMOVAL .
    GC0159736Courtesy of CHRYSLER GROUP, LLC
  36. Disengage the wire harness retainer from the shift cable bracket.
  37. Disengage the transmission vent hose from the shift cable bracket.
  38. Using a suitable prying tool (1), separate the shift cable end (2) from the manual lever on the transmission.
    GC0160099Courtesy of CHRYSLER GROUP, LLC
  39. Release the locks holding the shift cable housing (2) to the shift cable mounting bracket (1) on the transmission and separate the shift cable from the mounting bracket.
    GC0159235Courtesy of CHRYSLER GROUP, LLC
  40. Rotate the lock lever (1) counterclockwise and separate the transmission solenoid wire harness connector from the transmission.
  41. Remove the front lower load beams. Refer to LOAD BEAM, LOWER, REMOVAL .
  42. Remove the propeller shaft, if equipped. Refer to REMOVAL .
  43. Remove the crossunder exhaust pipe. Refer to REMOVAL .
  44. Remove the front halfshafts. Refer to REMOVAL .
  45. Remove the rear engine mount insulator. Refer to REMOVAL  .
  46. Remove the front suspension crossmember. Refer to CROSSMEMBER, REAR SUSPENSION, REMOVAL .
  47. Remove the Power Transfer Unit (PTU), if equipped. Refer to REMOVAL .
    GC0159835Courtesy of CHRYSLER GROUP, LLC
  48. Remove the bolt (1) holding the ground cable to the transmission and separate the ground cable from the transmission.
    GC0176954Courtesy of CHRYSLER GROUP, LLC
  49. If the transmission is to be removed from the engine, remove the torque converter bolt access cover (1) from the oil pan.
    GC0177028Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The crankshaft can be rotated using a wrench to turn the vibration damper bolt.

  50. If the transmission is to be removed from the engine, remove the six flexplate to torque converter bolts (1). Rotate the crankshaft counterclockwise (as viewed from the rear) to bring each of the bolts into view through the access opening.
    GC0186567Courtesy of CHRYSLER GROUP, LLC
  51. If the transmission is to be removed from the engine, remove the lower transmission mounting bolts (1).
    GC0186678Courtesy of CHRYSLER GROUP, LLC
  52. Raise and position the vehicle height to allow Power Train Dolly (special tool #6135, Dolly, Power Train) (3) and Engine Support Cradle (special tool #6710A, Cradle, Engine Support) (2) to be installed under the engine and transmission assembly.
  53. Loosen the cradle engine mounts to allow movement for positioning onto the engine locating holes on the engine block and oil pan rail. Align the engine to the engine support cradle. Position and adjust as necessary. Tighten the posts to the cradle frame. Secure the engine and transmission assembly to the dolly and cradle with safety straps (1).
    GC0186933Courtesy of CHRYSLER GROUP, LLC
  54. Remove the three left engine mount isolator to bracket bolts (4).
  55. Remove the right engine mount insulator. Refer to REMOVAL  .
  56. Slowly raise the vehicle to allow it to clear the powertrain assembly.
    CAUTION:

    Make sure that all components are clear of obstructions while raising the vehicle off of the powertrain assembly.

    GC0186561Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

  57. Affix a chain to the transmission mount bracket to be used as a lifting point.
  58. Using an engine hoist, remove the slack from the lifting chain.
  59. Remove the transmission from the engine. Refer to REMOVAL .
    GC0181031Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Perform the following steps to mount the engine to a maintenance stand if required.

  60. Install the (special tool #10272, Tool, Flywheel Locking) (1).
  61. Remove the bolts (2a) and the engine flexplate (2b). Discard the bolts, they can not be reused.
  62. Remove any sealant residues from the flexplate bolt holes.
    GC0182735Courtesy of CHRYSLER GROUP, LLC
  63. Install the maintenance stand mounting bracket (1) on the engine block. With the aid of a hydraulic lift, install the engine block and mounting bracket to the maintenance stand.
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