300M, Concorde, Intrepid, LHS, 1998-2004

Engine

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Removal & Installation



2.7L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.

    Click image to see an enlarged view

    Fig. Remove the cowl support for clearance to remove the engine-2.7L engine

  8.  
  9. Remove or disconnect the following:
    NOTE
    Remove the alternator with the engine.



    Negative battery cable at the remote terminal near the right strut tower
     
    Hood
     
    Wiper arms, cowl covers and cowl support
     
    Air intake duct and air cleaner assembly
     
    Upper radiator crossmember
     
    Hood release cable from the latch
     
    Cooling fan assembly
     
    Upper and lower radiator hoses
     
    A/C condenser-to-radiator fasteners
     
    Radiator
     
    Accessory drive belts
     
    Power steering pump and position it aside without disconnecting the lines
     



    A/C compressor and position it aside without disconnecting the lines
     
    V-band clamps at the exhaust manifolds
     
    Speed control and throttle cables from the throttle body
     
    Heater hoses and the coolant hoses at the recovery tank
     
    All vacuum lines, electrical connectors and ground straps from the engine
     
    Catalytic converter down pipes-to-rear mount fasteners
     
    Structural collar mounting bolts and collar

    Click image to see an enlarged view

    Fig. Removing the structural collar-2.7L engine

     

  10.  
  11. Matchmark the flexplate-to-torque converter and remove the torque converter bolts.

    Both transaxle cooler line-to-engine brackets
     
    Starter and Crankshaft Position (CKP) sensor
     
    2 lower transaxle-to-engine bolts
     
    Exhaust Gas Recirculation (EGR) valve assembly
     
    Fuel line and engine harness from the throttle body bracket
     

  12.  
  13. Remove the following brackets from the double-ended transaxle-to-engine bolts:
    WARNING
    Be careful not to damage the intake manifold or cylinder head covers when lifting the engine.



    Wiring harness bracket
     
    Transaxle shift cable bracket
     
    Throttle body support bracket
     
    Upper transaxle-to-engine bolts
     
    Both (right and left) engine mount isolators-to-engine mount bracket fasteners
     

  14.  
  15. Attach an engine lifting fixture to the engine.
  16.  
  17. Support the transaxle with a jack and remove the engine.

    Click image to see an enlarged view

    Fig. Engine support fixture attaching points-2.7L engine

  18.  

To install:

  1. Install the engine.
  2.  
  3. Align the engine mounts and install the fasteners, but do not tighten them at this time.
    WARNING
    Do not tighten the transaxle-to-engine bolts until all of the bolts have been hand-started and the engine is flush against the transaxle.

  4.  
  5. Install the transaxle-to-engine bolts. Torque the bolts to 75 ft. lbs. (102 Nm).
  6.  
  7. Remove the engine support fixture.
  8.  
  9. Torque the engine mount isolator-to-bracket fasteners to 45 ft. lbs. (61 Nm).
  10.  
  11. Align the matchmarks and install the flexplate-to-torque converter bolts. Torque the bolts to 55 ft. lbs. (75 Nm).
  12.  
  13. Install the starter and the CKP sensor.
  14.  
  15. Install the structural collar using the following sub-steps:
    1. Torque the vertical collar-to-oil pan bolts to 10 inch lbs. (1.1 Nm).
    2.  
    3. Torque the collar-to-transaxle bolts to 40 ft. lbs. (55 Nm).
    4.  
    5. Torque the center vertical bolt to 40 ft. lbs. (55 Nm); then, the remaining vertical bolts to the same torque.
    6.  

  16.  
  17. Complete the installation by reversing the removal procedure. Keep the following in mind:

    Use new V-band clamps and torque them to 100 inch lbs. (11 Nm)
     
    Torque the A/C compressor and power steering pump fasteners to 21 ft. lbs. (28 Nm)
     
    Negative battery cable
     

  18.  
  19. Fill the cooling system to the proper level.
  20.  
  21. Fill the engine with clean oil.
  22.  
  23. Start the vehicle, check for leaks and repair if necessary.
  24.  

3.2L And 3.5L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Properly relieve the fuel system pressure.

    Click image to see an enlarged view

    Fig. Be careful not to damage the windshield when removing the cowl covers and supports 3.5L models

  8.  
  9. Remove or disconnect the following:
    WARNING
    The intake manifold is a composite design and should be removed before lifting the engine or it may be damaged and require replacement.



    Negative battery cable
     
    Hood
     
    Wiper arms
     
    Cowl covers and supports
     
    Air cleaner and air inlet duct
     
    Upper radiator support and hood release cable
     
    Fan module
     
    Accessory drive belts
     
    Upper and lower radiator hoses
     
    Engine oil and transmission cooler lines at the radiator
     
    Alternator, if necessary.
     
    A/C compressor mounting bolts and position it aside with the lines connected
     
    Power steering pump mounting bolts and position the pump aside
     
    V-band clamp at the right exhaust manifold
     
    Right side catalytic converter down pipe bracket fasteners
     
    Fuel lines
     
    Throttle and cruise control cables
     
    All vacuum hoses
     
    Ground straps at both cylinder heads
     



    Upper intake manifold and cover the openings
     
    Heater hoses
     
    Throttle body support brackets
     
    Upper transaxle-to-engine mounting bolts
     
    All electrical and vacuum hose connections
     
    Structural collar and matchmark the flexplate-to-torque converter position
     
    Flexplate-to-torque converter mounting bolts
     
    Left exhaust manifold V-band clamp and left catalytic converter support brackets
     
    Starter
     
    Left and right engine mounting bolts
     
    Crankshaft Position (CKP) sensor
     
    Lower engine-to-transaxle mounting bolts
     

  10.  
  11. Attach a suitable lifting device to the engine.
  12.  
  13. Support the transaxle using a floor jack with a small block of wood in between.
  14.  
  15. Slowly lift the engine from the vehicle.
  16.  

To install:

  1. Install the engine.
  2.  
  3. Align the engine mounts and install the fasteners, but do not tighten them until all of the mounting bolts have been installed.
  4.  
  5. Install the engine-to-transaxle mounting bolts and torque to 75 ft. lbs. (102 Nm).
  6.  
  7. Remove the engine lifting device.
  8.  
  9. Torque the engine mount nuts/bolts 45 ft. lbs. (61 Nm).
  10.  
  11. Align the flexplate-to-torque converter matchmarks and torque the bolts to 55 ft. lbs. (75 Nm).
  12.  
  13. Install or connect the following:

    CKP sensor and the starter
     
    Left-side exhaust manifold V-band clamp and torque to 100 inch lbs. (11 Nm)
     
    Left-side catalytic converter mounting bracket fasteners
     

  14.  
  15. Install the structural collar using the following procedure:
    1. Install the vertical collar-to-oil pan bolts and tighten, temporarily to 10 inch lbs. (1.1 Nm).
    2.  
    3. Install the collar-to-transaxle bolts and torque to 40 ft. lbs. (55 Nm).
    4.  
    5. Starting with the center vertical bolt and working outward, torque the bolts to 40 ft. lbs. (55 Nm).
    6.  

  16.  
  17. Install or connect the following:

    Throttle body support bracket
     
    Heater hoses, all ground straps and vacuum hoses
     
    Upper intake manifold
     
    All engine wiring harnesses
     

  18.  
  19. Adjust the throttle and cruise control cables.

    Fuel lines
     
    V-band clamp on the right exhaust manifold and torque to 100 inch lbs. (11 Nm)
     
    Right-side catalytic converter mounting bracket fasteners
     
    A/C compressor and torque the bolts to 21 ft. lbs. (28 Nm)
     
    Alternator and its wiring harness
     
    Radiator
     
    Power steering pump
     
    Engine oil and transaxle cooler lines
     
    Radiator hoses and accessory drive belt
     
    Hood release cable and upper radiator support
     
    Air cleaner and inlet hose
     
    Cowl covers, supports and wiper arms
     
    Hood
     
    Negative battery cable
     

  20.  
  21. Fill the cooling system to the proper level.
  22.  
  23. Fill the engine with clean oil.
  24.  
  25. Start the vehicle, check for leaks and repair if necessary.
  26.  

 
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