Avenger 2008

Engine 3

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Removal & Installation



3.5L Engine

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009


NOTE
Capture and store any residual fluid drainage, or leakage from ancillary components, in the appropriately marked containers.

  1. Remove the engine cover.
  2.  
  3. Disconnect negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Evacuate and recover the air conditioning system.
  8.  
  9. Perform the fuel pressure release procedure.
  10.  
  11. Disconnect fuel line (1) from the fuel rail inlet (2) and position aside.

    Click image to see an enlarged view

    Fig. Disconnect the fuel line (1) at the fuel rail inlet (2)

  12.  
  13. Remove the Air Cleaner Housing.

    Click image to see an enlarged view

    Fig. Remove the Air Cleaner Housing

  14.  
  15. Remove the Upper Intake Manifold (2).

    Click image to see an enlarged view

    Fig. Remove the upper intake manifold (2)

  16.  
  17. Raise the vehicle.
  18.  
  19. Remove the 12 belly pan fasteners (1) and remove the belly pan (2).

    Click image to see an enlarged view

    Fig. Remove the 12 belly pan fasteners (1) and remove the belly pan (2)

  20.  
  21. Disconnect the exhaust extension pipe (1) and gasket (2) from the cross-under pipe (3).

    Click image to see an enlarged view

    Fig. Disconnect the exhaust extension pipe (1) and gasket (2) from the cross-under pipe (3)

  22.  
  23. Remove the center brace (1).

    Click image to see an enlarged view

    Fig. Remove the center brace (1)

  24.  
  25. Remove the cross under pipe.
  26.  
  27. Remove the right front halfshaft assembly.
  28.  
  29. Remove rear maniverter.
  30.  
  31. Remove the PTU.
  32.  
  33. Remove the right forward splash shield.

    Click image to see an enlarged view

    Fig. Remove left and right splash shields (2)

  34.  
  35. Remove the left forward splash shield.
  36.  
  37. Remove front fascia closeout (1).

    Click image to see an enlarged view

    Fig. Remove front fascia closeout (1)

  38.  
  39. Remove the front engine mount bracket (2).

    Click image to see an enlarged view

    Fig. Remove the front engine mount bracket (2)

  40.  
  41. Disconnect starter motor electrical connectors. Remove starter motor and shim.
  42.  
  43. Disconnect the lower coolant hose (1) from the return tube (2).

    Click image to see an enlarged view

    Fig. Disconnect the lower coolant hose (1) from the return tube (2)

  44.  
  45. Lower vehicle.
  46.  
  47. Remove the left front halfshaft.
  48.  
  49. Remove the left front inner wheel well.
  50.  
  51. Disconnect the electrical connector (2) at the Crankshaft Position (CKP) sensor (3).

    Click image to see an enlarged view

    Fig. Disconnect the electrical connector (2) at the Crankshaft Position (CKP) sensor (3)

  52.  
  53. Remove hold down bolt (1) at the Crankshaft Position (CKP) sensor (3).
  54.  
  55. Remove the Crankshaft Position (CKP) sensor (3).
  56.  
  57. Disconnect the positive auxiliary battery post cable (2) from the left shock tower and position aside.

    Click image to see an enlarged view

    Fig. Disconnect the positive auxiliary battery post cable (2) from the left shock tower

  58.  
  59. Disconnect the 2 PCM harness connectors (1) and position aside.

    Click image to see an enlarged view

    Fig. Disconnect the 2 PCM harness connectors (1)

  60.  
  61. Disconnect the heater core supply hose (1) from the intake manifold outlet (2).

    Click image to see an enlarged view

    Fig. Disconnect the heater core supply hose (1) from the intake manifold outlet (2)

  62.  
  63. Disconnect the coolant reservoir overflow hose (2) from the coolant bottle (4) and position aside.

    Click image to see an enlarged view

    Fig. Disconnect the coolant reservoir overflow hose (2) from the coolant bottle (4)

  64.  
  65. Disconnect the Upper Radiator hose from the thermostat housing and position aside.
  66.  
  67. Disconnect both A/C lines (1) and (2) from the A/C compressor (3).

    Click image to see an enlarged view

    Fig. Disconnect both A/C lines (1) and (2) from the A/C compressor (3)

  68.  
  69. Disconnect the A/C pressure transducer harness connector (1).

    Click image to see an enlarged view

    Fig. Disconnect the A/C pressure transducer harness connector (1)

  70.  
  71. Disconnect and remove the A/C discharge line (3) from the condenser (4).
  72.  
  73. Remove the front maniverter.
  74.  
  75. Remove the fan module.
  76.  
  77. Disconnect the power steering pressure and supply hoses from the power steering pump.
  78.  
  79. Support engine with a suitable lifting device or support fixture.
  80.  
  81. Remove the transmission.
  82.  
  83. Install lift/support brackets 8534-7 and 8534-8 to engine.
  84.  
  85. Install engine lifting chains.
  86.  
  87. Attach lifting chains to engine lift.
  88.  
  89. Remove 3 right engine mount bolts.

    Click image to see an enlarged view

    Fig. Remove 3 right engine mount bolts

  90.  
  91. Remove ground strap from the hood and position hood back.
  92.  
  93. Remove the engine.
  94.  

To install:

  1. Install the engine and support it with a suitable lifting device or support fixture.
  2.  
  3. Install ground strap to the hood and position the hood back.
  4.  
  5. Install 3 right engine mount bolts.
  6.  
  7. Install the transmission.
  8.  
  9. Disconnect the lifting chains from engine lift.
  10.  
  11. Remove the engine lifting chains.
  12.  
  13. Remove lift/support brackets 8534-7 and 8534-8 from the engine.
  14.  
  15. Install the power steering pressure and supply hoses to the power steering pump.
  16.  
  17. Install the fan module.
  18.  
  19. Install starter motor and dust shield, connect starter motor electrical connectors.
  20.  
  21. Install the lower coolant hose.
  22.  
  23. Install the front maniverter.
  24.  
  25. Install the A/C discharge line to the condenser.
  26.  
  27. Connect the A/C pressure transducer harness connector.
  28.  
  29. Connect both A/C lines to the A/C compressor.
  30.  
  31. Connect the upper radiator hose to the thermostat housing.
  32.  
  33. Connect the coolant reservoir overflow hose to the coolant bottle.
  34.  
  35. Connect the heater core supply hose to the intake manifold outlet.
  36.  
  37. Connect the 2 PCM harness connectors.
  38.  
  39. Connect the positive and negative auxiliary battery post cables.
  40.  
  41. Install the crankshaft position sensor.
  42.  
  43. Install the crankshaft position sensor hold down bolt.
  44.  
  45. Connect the crankshaft position sensor harness connector.
  46.  
  47. Raise the vehicle.
  48.  
  49. Install the left front splash shield.
  50.  
  51. Install the left front halfshaft.
  52.  
  53. Install the front engine mount bracket.
  54.  
  55. Install the front closeout panel.
  56.  
  57. Install the left forward splash shield.
  58.  
  59. Install the right forward splash shield.
  60.  
  61. Install the PTU.
  62.  
  63. Install the rear maniverter.
  64.  
  65. Install the left halfshaft.
  66.  
  67. Install the cross under pipe.
  68.  
  69. Install the center brace.
  70.  
  71. Install the exhaust extension pipe and gasket to the cross-under pipe.
  72.  
  73. Install the belly pan and the 12 belly pan fasteners.
  74.  
  75. Lower the vehicle.
  76.  
  77. Connect the fuel line to the fuel rail.
  78.  
  79. Install the Upper intake manifold.
  80.  
  81. Install the air filter housing.
  82.  
  83. Connect negative battery cable.
  84.  
  85. Charge the refrigerant system.
  86.  
  87. Fill the cooling system.
  88.  
  89. Install the engine cover.
  90.  

 
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