Chrysler Cirrus/Stratus/Sebring/Avenger/Breeze 1995-1998

Engine

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Removal & installation

In the process of removing the engine, you will come across a number of steps which call for the removal of a separate component or system, such as "disconnect the exhaust system'' or "remove the radiator.'' In most instances, a detailed removal procedure can be found elsewhere in this guide.

It is virtually impossible to list each individual wire and hose which must be disconnected, simply because so many different model and engine combinations have been manufactured. Careful observation and common sense are the best possible approaches to any repair procedure.

Removal and installation of the engine can be made easier if you follow these basic points:



If you have to drain any of the fluids, use a suitable container.
 
Always tag any wires or hoses and, if possible, the components they came from before disconnecting them.
 
Because there are so many bolts and fasteners involved, store and label the retainers from components separately in muffin pans, jars or coffee cans. This will prevent confusion during installation.
 
After unbolting the transmission or transaxle, always make sure it is properly supported.
 
If it is necessary to disconnect the air conditioning system, have this service performed by a qualified technician using a recovery/recycling station. If the system does not have to be disconnected, unbolt the compressor and set it aside.
 
When unbolting the engine mounts, always make sure the engine is properly supported. When removing the engine, make sure that any lifting devices are properly attached to the engine. It is recommended that if your engine is supplied with lifting hooks, your lifting apparatus be attached to them.
 
Lift the engine from its compartment slowly, checking that no hoses, wires or other components are still connected.
 
After the engine is clear of the compartment, place it on an engine stand or workbench.
 
After the engine has been removed, you can perform a partial or full teardown of the engine using the procedures outlined in this guide.
 

Cirrus, Stratus, Sebring Convertible and Breeze

See Figures 1 and 2

The following procedure requires the discharging/evacuation of the vehicle's air conditioning system. In many areas, it is illegal for anyone other than a MVAC-trained, EPA-certified, automotive technician to service the A/C system or its components. If the vehicle must be driven to and from such a facility, be sure to have this service performed before you begin the removal procedure.


CAUTION
Fuel injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure MUST be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Relieve the fuel system pressure. Disconnect the fuel line quick-connect fitting from the fuel rail by squeezing the retainer tabs together and pulling the fuel tube/quick-connect fitting assembly off the fuel tube nipple.
  2.  
  3. Remove the battery from the vehicle.
  4.  
  5. Remove the battery tray from the vehicle. Remove the battery blanket heater, if equipped.
  6.  
  7. Remove the complete air cleaner and inlet duct assembly.
  8.  
  9. Unbolt the Powertrain Control Module (PCM) and move it aside.
  10.  
  11. Drain and properly contain the coolant from the engine.
  12.  
  13. Remove the upper and lower radiator hoses, radiator and cooling fan.
  14.  
  15. Disconnect and plug the automatic transaxle cooler lines, if equipped.
  16.  
  17. Disconnect the clutch cable and transaxle shift linkage, if equipped.
  18.  
  19. Disconnect the throttle body linkage and the engine wiring harness.
  20.  
  21. Disconnect the heater hoses.
  22.  
  23. If not already done, have a qualified, trained technician recover and properly contain the refrigerant of the A/C system with an R-134a recovery unit.
  24.  
  25. Raise and safely support the vehicle. Remove the front wheels.
  26.  
  27. Drain the engine oil.
  28.  
  29. Remove the right side inner splash shield.
  30.  



Click image to see an enlarged view

Fig. Fig. 1: Removal of the right inner splash shield

  1. Remove the accessory drive belts.
  2.  
  3. Remove the right and left halfshaft assemblies.
  4.  
  5. Disconnect the exhaust pipe from the exhaust manifold.
  6.  
  7. Remove the front and rear engine mount brackets from the body.
  8.  
  9. Lower the vehicle.
  10.  
  11. Remove the power steering pump and reservoir.
  12.  
  13. Remove the A/C compressor as follows:
    1. Disconnect the compressor clutch wire lead.
    2.  
    3. Disconnect and plug the refrigerant lines from the compressor.
    4.  
    5. Remove the compressor mounting bolts.
    6.  
    7. Remove the compressor unit from the vehicle. Be sure to plug all openings in the A/C system to prevent moisture contamination.
    8.  

  14.  
  15. Disconnect the ground straps from the engine.
  16.  



Click image to see an enlarged view

Fig. Fig. 2: Positioning the engine on an appropriate engine dolly fixture

  1. Raise the vehicle, then position an engine dolly under the vehicle to support the engine.
  2.  
  3. Remove the transaxle and engine mount through-bolts.
  4.  
  5. Raise the vehicle slowly, allowing the engine and transaxle assembly to remain on the dolly.
  6.  

To install:
  1. Installation is the reverse of the removal procedure. Please note the following important steps.
  2.  
  3. Position the engine and the transaxle under the vehicle, then lower the vehicle onto the engine assembly.
  4.  
  5. Tighten the A/C compressor mounting bolts to 30 ft. lbs. (41 Nm).
  6.  
  7. Adjust the accessory drive belts.
  8.  
  9. Refill the cooling system with a 50/50 mixture of clean water and ethylene glycol or other suitable antifreeze.
  10.  
  11. Install fresh engine oil and a new oil filter.
  12.  
  13. Tighten the battery hold-down bracket bolt to 124 inch lbs. (14 Nm).
  14.  
  15. Tighten the battery cables to 150 inch lbs. (17 Nm).
  16.  
  17. Have a qualified, trained technician recharge the vehicle's air conditioning system.
  18.  
  19. Check to be sure all ducts, hoses, fuel lines and wiring harnesses have been properly reconnected.
  20.  
  21. Start and run the engine until it reaches operating temperature.
  22.  
  23. Check for leaks and proper operation.
  24.  

Sebring Coupe and Avenger

See Figures 3 and 4


CAUTION
Fuel injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure MUST be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

The transaxle must be removed before removing the engine. They will not come out as a unit.

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine coolant.
  4.  
  5. Drain the engine oil and the transmission oil.
  6.  
  7. Safely relieve the pressure within the fuel injection system.
  8.  
  9. Matchmark the hood to the hinges and remove the hood. For further details, refer to Body & Trim .
  10.  
  11. Remove the engine undercover.
  12.  
  13. Remove the transaxle assembly, using the recommended procedure in Drive Train .
  14.  
  15. Remove the radiator, after disconnecting the hoses at the engine.
  16.  
  17. Disconnect the accelerator cable and remove the bracket.
  18.  
  19. Disconnect the heater hoses.
  20.  
  21. Disconnect the brake booster vacuum hose at the engine.
  22.  
  23. Label and disconnect the vacuum hoses running to the bulkhead.
  24.  
  25. Disconnect the high pressure fuel line and discard the O-ring. It is not reusable.
  26.  
  27. Remove the fuel return hose.
  28.  
  29. Label and disengage the electrical connectors to the engine components. All wires and connectors should be labeled at the time of engine removal. This should save much time at assembly.
  30.  
  31. Remove the accessory drive belts. Remove the bolts holding the power steering pump to its bracket and hang the pump out of the way. Do not disconnect the hoses and do not allow the pump to hang by the hoses. Remove the power steering pump bracket.
  32.  
  33. Remove the air conditioning compressor from its mount and hang it from a stiff wire out of the way. Note that the hoses should be left attached. Do not loosen them or discharge the system.
  34.  
  35. Remove the bolts at the exhaust system joint just below the manifold. Separate the exhaust pipes. Discard the gasket and the two nuts.
  36.  
  37. Raise and safely support the vehicle. Install the engine hoist equipment and make certain the attaching points on the engine are secure. Draw tension on the hoist just enough to support the engine's weight, but no more. Do not disturb the placement of the vehicle on the stands.
  38.  
  39. Remove the through-bolt from the rear (firewall side) roll stopper. Remove the through-bolt from the front engine roll stopper.
  40.  



Click image to see an enlarged view

Fig. Fig. 3: Right side engine mounting-2.0L engine



Click image to see an enlarged view

Fig. Fig. 4: Right side engine mounting-2.5L engine

  1. Remove the nuts and bolts holding the upper (right side) engine mount to the engine. Remove the through-bolt and remove the mount assembly. Also remove the support bracket below the mount.
  2.  
  3. Double check for any remaining cables, wires or hoses running to the engine. Elevate the hoist and remove the engine from the vehicle. Immediately place the engine on an engine stand or support it with wooden blocks. Do not allow it to rest on the oil pan or lie on its side. Do not leave the engine hanging from the hoist.
  4.  

To install:

After repairs, make certain the engine is fully reassembled before installation. All components removed with the engine out of the vehicle (or equivalent replacement parts) should be in place before reinstallation.

  1. Installation is the reverse of the removal procedure. Please note the following important steps.
  2.  
  3. Connect the exhaust system to the manifold, using a new gasket. Tighten the bolts to 33 ft. lbs. (44 Nm).
  4.  
  5. Tighten the engine mount nuts and bolts. Correct torque values are:

    Nut and bolt holding the right side mount to engine: 63 ft. lbs. (86 Nm)
     
    Right side mount through-bolt: 71-85 ft. lbs. (98-118 Nm)
     
    Rear roll stopper through-bolt: 32 ft. lbs. (44 Nm)
     
    Front roll stopper through-bolt: 41 ft. lbs. (56 Nm)
     

  6.  

Allow the mounts to support the engine weight before final tightening the front roll stopper through-bolt.

  1. On the 2.0L engine, tighten the power steering pump bracket bolts to 16 ft. lbs. (22 Nm). On the 2.5L engine, tighten the power steering pump bracket bolts to 29 ft. lbs. (39 Nm).
  2.  
  3. Connect the wiring and harness connectors to the engine. Make certain each terminal is clean and the connector is firmly seated to its mate. Do not route wires near hot surfaces or moving parts.
  4.  
  5. Using a new O-ring lightly lubricated with clean engine oil, connect the high pressure fuel line and tighten the bolts to 22 inch lbs. (2.5 Nm).
  6.  
  7. Check the engine oil drain plug, and make sure that it is securely installed. Add the proper amount of clean engine oil.
  8.  
  9. Check the transaxle drain plug, tightening it if necessary, and install the proper amount of transmission oil.
  10.  
  11. Check the radiator and engine draincocks, making sure they are closed. Refill the cooling system with a 50/50 mixture of clean water and ethylene glycol or other suitable antifreeze.
  12.  
  13. Double check all installation items, paying particular attention to loose hoses or hanging wires, loosened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
  14.  
  15. Connect the negative battery cable. Start the engine and check for leaks.
  16.  
  17. Attend to all leaks immediately, remembering that fluids and metal surfaces may be hot. Adjust the drive belts to the correct tension. Adjust all cables (transmission, throttle, shift selector) and check the fluid levels. Check the operation of all gauges and dashboard lights.
  18.  
  19. In a safe location at low speed, road test the vehicle for correct operation of steering, brakes, transaxle, clutch and speedometer.
  20.  

 
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