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Removal - Engine Assembly

WARNING: This page is about a different car, the 2004 Dodge Intrepid, 2004 Chrysler Intrepid, and 2004 Chrysler Concorde. However, it is still accessible from the selected car via links, so may be relevant.
  1. Release fuel pressure. (Refer to FUEL DELIVERY ).
  2. Disconnect negative cable at remote jumper terminal located at right strut tower (Fig 1).
    Fig 1: Removing Negative Cable Remote Terminal
    G02709495Courtesy of DAIMLERCHRYSLER CORP.
  3. Mark hood position at hinges and remove hood. Refer to HOOD .
  4. Drain cooling system. (Refer to COOLING ).
  5. Remove both wiper arms. Refer to WIPER ARMS .
  6. Remove right and left cowl screens. Refer to COWL GRILLE AND SCREEN .
  7. Remove strut tower brace. Refer to FRONT STRUT TOWER TO TOWER BRACE .
  8. Remove air cleaner assembly and air inlet hose (Fig 2).
    Fig 2: Removing Air Cleaner And Inlet Hose
    G02709496Courtesy of DAIMLERCHRYSLER CORP.
  9. Remove upper radiator crossmember. Refer to GRILLE OPENING REINFORCEMENT .
  10. Disconnect hood release cable from hood latch.
  11. Remove radiator fan. (Refer to ELECTRIC COOLING FANS ).
  12. Disconnect radiator upper hose at engine.
  13. Disconnect radiator lower hose at radiator.
  14. Remove radiator. (Refer to RADIATOR ).
  15. Remove accessory drive belts. (Refer to ACCESSORY DRIVE ).
  16. Remove power steering pump mounting bolts and set pump aside. Refer to PUMP .
    NOTE: Generator can be removed with engine assembly.
  17. Disconnect A/C compressor electrical connector.
  18. Remove A/C compressor mounting bolts and set compressor aside.
  19. Loosen and remove V-Band clamps at exhaust manifolds.
  20. Disconnect throttle and speed control cables. Refer to THROTTLE CONTROL CABLE .
  21. Disconnect coolant hoses at coolant pressure/recovery container.
  22. Disconnect heater hoses.
  23. Perform fuel pressure release procedure and disconnect fuel line. Refer to FUEL DELIVERY .
  24. Disconnect all vacuum lines and electrical connectors.
  25. Disconnect all ground straps attaching to engine.
  26. Hoist vehicle and drain engine oil.
  27. Remove fasteners supporting catalytic converter down pipes at front and rear mounts.
  28. Remove structural collar. (Refer to REMOVAL ).
  29. Mark flex plate to torque converter position. Remove torque converter bolts.
  30. Disconnect both transaxle cooler line brackets from engine.
  31. Remove starter. (Refer to STARTERS ).
  32. Remove crankshaft position sensor. (Refer to CRANKSHAFT POSITION SENSOR ).
  33. Remove the two lower transaxle to block bolts.
  34. Lower vehicle.
  35. Remove screws attaching fuel line and electrical harness to the throttle body bracket.
  36. Remove the fasteners attaching the following brackets to the transaxle to block double-ended bolts:
    • Electrical harness attaching bracket.
    • Transaxle shift cable attaching bracket.
    • Throttle body support bracket.
  37. Remove the upper transaxle to block bolts.
  38. Remove right and left engine mount isolator to engine mount bracket fasteners.
    CAUTION: Intake manifolds and cylinder head covers are a composite design. Therefore, care should be taken when lifting the engine from engine compartment.
  39. Attach Special Tool 8342, Engine Lifting Fixture to engine at the locations shown in (Fig 3).
    Fig 3: Identifying Engine Lifting Fixture
    G02709497Courtesy of DAIMLERCHRYSLER CORP.
  40. Support transaxle with a floor jack.
  41. Hoist engine from engine compartment.
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