Removal and Replacement
REMOVAL
1. Disconnect the battery negative cable.
2. Remove hood. Mark hood hinge location for reinstallation.
3. Remove air cleaner assembly.
4. Remove radiator core support bracket.
5. Remove fan shroud with electric fan assembly.
6. Remove drive belt.
NOTE: It is NOT necessary to discharge the AIC system to remove the engine.
7. Remove A/C compressor and secure away from engine with lines attached.
8. Remove generator and secure away from engine.
NOTE: Do NOT remove the phenolic pulley from the P/S pump. It is not required for P/S pump removal.
9. Remove power steering pump with lines attached and secure away from engine.
10. Drain cooling system.
11. Remove coolant bottle.
12. Disconnect the heater hoses from the engine.
13. Disconnect heater hoses from heater core and remove hose assembly.
14. Disconnect throttle and speed control cables.
15. Remove upper radiator hose from engine.
16. Remove lower radiator hose from engine.
17. Disconnect the engine to body ground straps at the left side of cowl.
18. Disconnect the engine wiring harness at the following points:
^ Intake air temperature (IAT) sensor
^ Fuel Injectors
^ Throttle Position (TPS) Switch
^ Idle Air Control (IAC) Motor
^ Engine Oil Pressure Switch
^ Engine Coolant Temperature (ECT) Sensor
^ Manifold Absolute Pressure MAP) Sensor
^ Camshaft Position (CMP) Sensor
^ Coil Over Plugs
^ Crankshaft Position Sensor
19. Remove coil over plugs.
20. Release fuel rail pressure.
21. Remove fuel rail and secure away from engine.
22. Remove the PCV hose.
23. Remove the breather hoses.
24. Remove the vacuum hose for the power brake booster.
25. Disconnect knock sensors.
26. Secure the left and right engine wiring harnesses away from engine.
27. Raise vehicle.
28. Disconnect oxygen sensor wiring.
29. Disconnect crankshaft position sensor.
30. Disconnect the engine block heater power cable, if equipped.
31. Disconnect the front propsh aft at the front differential and secure out of way.
32. Remove the starter.
33. Remove the ground straps from the engine
34. Disconnect the exhaust pipes at the manifold.
35. Remove the structural cover, if equipped.
36. Remove torque convertor bolts, and mark location for reassembly.
37. Remove transmission bellhousing to engine bolts.
38. Loosen left and right engine mount thru bolts.
NOTE: It is not necessary to completely remove engine mount thru bolts, for engine removal.
39. Lower the vehicle.
40. Support the transmission with a suitable jack.
41. Connect a suitable engine hoist to the engine.
CAUTION: The 3.7L engine with manual transmissions, can be removed without removing the manual transmission. Use caution when attempting this procedure as the clearance is tight.
42. Remove engine from vehicle.
INSTALLATION
1. Position the engine in the vehicle.
CAUTION: Use caution when installing 3.7L engine into vehicle equipped with manual transmission, as clearance is tight.
2. Install both left and right side engine mounts into the frame mounts.
3. Raise the vehicle.
4. Install the transmission bellhousing to engine mounting bolts. Tighten the bolts to 41 Nm (30 ft. lbs.).
5. Tighten the engine mount thru bolts.
6. Install the torque convertor bolts.
7. Connect the ground straps on the left and right side of the engine.
8. Install the starter.
9. Connect the crankshaft position sensor.
10. Install the engine block heater power cable, if equipped.
CAUTION: The structural cover requires a specific torque sequence. Failure to follow this sequence may cause severe damage to the cover.
11. Install the structural cover. Position the structural cover in the vehicle.
12. Install all bolts (1) retaining the cover-to-engine. DO NOT TIGHTEN THE BOLTS AT THIS TIME.
13. Install the cover-to-transmission bolts. DO NOT TIGHTEN AT THIS TIME.
CAUTION: THE STRUCTURAL COVER MUST BE HELD TIGHTLY AGAINST BOTH THE ENGINE AND THE TRANSMISSION BELL HOUSING DURING TIGHTENING SEQUENCE. FAILURE TO DO SO MAY CAUSE DAMAGE TO THE COVER.
14. Starting with the two rear cover-to-engine bolts, tighten bolts (1) (Structure Cover) to 54 N.m (40 ft. lbs.), then tighten bolts (2) (Structural Cover) and to 54 N.m (40 ft. lbs.) in the sequence shown.
15. Install the structural cover.
16. Install the exhaust pipe.
17. Connect the oxygen sensors.
18. Lower vehicle.
19. Connect the knock sensors.
20. Connect the engine to body ground straps.
21. Install the power brake booster vacuum hose.
22. Install the breather hoses.
23. Install the PCV hose.
24. Install the fuel rail.
25. Install the coil over plugs.
26. Reconnect the engine wiring harness at the following points:
^ Intake air temperature (IAT) sensor
^ Fuel Injectors
^ Throttle Position (TPS) Switch
^ Idle Air Control (IAC) Motor
^ Engine Oil Pressure Switch
^ Engine Coolant Temperature (ECT) Sensor
^ Manifold Absolute Pressure MAP) Sensor
^ Camshaft Position (CMP) Sensor
^ Coil Over Plugs
^ Crankshaft Position Sensor
27. Connect lower radiator hose.
28. Connect upper radiator hose.
29. Connect throttle and speed control cables.
30. Install the heater hose assembly.
31. Install coolant recovery bottle.
32. Install the power steering pump.
33. Install the generator.
34. Install the A/C compressor.
35. Install the drive belt.
36. Install the fan shroud with the electric fan assembly.
37. Install the radiator core support bracket.
38. Install the air cleaner assembly.
39. Refill the engine cooling system.
40. Install the hood.
41. Check and fill engine oil.
42. Connect the battery negative cable.
43. Start the engine and check for leaks