Engine - Removal

REMOVAL





1. Remove the hood from the vehicle (2) Hood - Removal





2. Remove the engine cover (1).
3. Perform the Fuel System Pressure Release procedure Service and Repair
4. Disconnect the fuel supply line Service and Repair





5. Disconnect and isolate the negative battery cable (2).





6. Loosen the air duct clamp and disconnect the air duct at the air cleaner cover.
7. Remove air cleaner assembly retaining bolt (2).
8. Lift entire air cleaner housing assembly (1) from the locating pin (3).





9. Remove the cowl top panel (1) Cowl Panel Cover - Removal






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

10. Rotate accessory drive belt tensioner (6) counterclockwise until it contacts it's stop. Remove the accessory drive belt, then slowly rotate the tensioner into the freearm position.
11. Place gearshift lever in NEUTRAL, raise and support the vehicle on a hoist and drain the engine oil.

WARNING: Do not remove the radiator pressure cap, cylinder block drain plugs or loosen the radiator draincock with the system hot and under pressure. Serious burns from coolant can occur.

12. Drain the cooling system Service and Repair





13. Remove the screws (1) and the front belly pan (2).





14. Remove the screws (1) and the rear belly pan (2).





15. FOR AWD ONLYRemove the propeller shaft heat shield (1).





16. FOR AWD ONLYPlace alignment index marks on the propeller shaft and front axle flanges.
17. FOR AWD ONLYRemove and discard the four front propeller shaft-to-axle flange bolts (2).
18. FOR AWD ONLYPlace alignment index marks on the propeller shaft and transfer case flanges.
19. FOR AWD ONLYRemove and discard the four front propeller shaft-to-transfer case flange bolts (2).
20. FOR AWD ONLYRemove the propeller shaft assembly (1).





21. Remove the engine mount heat shield fasteners (2,3) and remove the heat shield (1).





22. Remove the engine mount to frame nuts (1,2).





23. FOR AWD ONLY Remove the left (2) and right front drive axles.





24. FOR AWD ONLY Remove the differential support bracket bolts (2) from the differential (3) to the engine block and remove the differential support bracket (1).





25. FOR AWD ONLY Remove the differential (4) to oil pan bolts (3).
26. FOR AWD ONLY Rotate the differential (4) so the drive flange is facing forward and the oil pan side is facing up. Remove the differential out through the opening at the rear of the cradle.
27. FOR AWD ONLY Remove the intermediate shaft (2) from the oil pan (3).
28. Disconnect the transmission oil cooler lines from their retainers at the oil pan bolts.






CAUTION: When servicing or replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor.

29. Disconnect the oxygen sensor connectors (2).
30. Saturate all exhaust bolts and nuts with Mopar(R) Rust Penetrant. Allow 5 minutes for penetration.
31. Remove the exhaust pipe to manifold bolts (3) (left side shown, right side similar) and disconnect the front exhaust pipe/catalytic converter assembly Catalytic Converter - Removal






NOTE: The starter is located on the right side of the transmission for RWD vehicles and is located on the left side for AWD vehicles.

32. Disconnect the starter wires and remove the starter motor (1) Starter - Removal





33. Remove the transmission (3) to engine oil pan (2) bolts (1).





34. Remove the torque converter access cover (1).





35. Remove the drive plate to converter bolts (1).





36. Remove the transmission bell housing to engine block bolts (2).
37. Lower the vehicle.





38. Disconnect the heater hoses (1).





39. Remove the upper radiator hose (3).
40. Disconnect the cooling fan electrical connector (2).
41. Remove the cooling fan mounting bolts.
42. Remove the radiator cooling fan and shroud assembly (1) from vehicle Cooling Fan - Removal





43. Remove the A/C compressor (3) with the lines attached. Secure compressor out of the way.





44. Remove the generator support bracket retainers (3,4) and remove the support bracket (1).
45. Remove the generator (2) Generator - Removal
46. Remove the intake manifold as an assembly Intake Manifold - Removal
47. Remove the ground wires from the rear of each cylinder head.






NOTE: It is not necessary to disconnect the P/S hoses from the P/S pump, for P/S pump removal.

48. Remove the three P/S pump retainer bolts (2) through access holes in the pulley. Secure P/S pump out of the way.





49. Install the engine lift fixture (2), special tool 8984A and 8984-UPD (4).
50. Separate the engine from the transmission and remove engine from the vehicle, and install the engine on a repair stand.