Chrysler Front Wheel Drive Cars 6-CYL 1988-1995 Repair Information

Engine

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REMOVAL & INSTALLATION



Except Premier and Monaco

See Figures 1 through 5

  1. Relieve the fuel system pressure. For more details refer to Fuel System .
  2.  
  3. Disconnect both battery cables (negative first) from the battery.
  4.  
  5. Matchmark the hinge-to-hood position with a grease pencil, paint, or with a similar method. Remove the hood.
  6.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Drain the cooling system (refer to General Information & Maintenance ). Detach and label all engine electrical connections.
  2.  
  3. Remove the coolant hoses from the radiator and engine. Remove the radiator and cooling fan assembly.
  4.  



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Fig. Fig. 1: Engine mounts and related hardware-3.0L engines, except Premier and Monaco



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Fig. Fig. 2: Accessory mounting brackets-3.0L engines, except Premier and Monaco



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Fig. Fig. 3: Engine mounts and related hardware-3.3L and 3.8L engines



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Fig. Fig. 4: Right inner splash shield-except Premier and Monaco



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Fig. Fig. 5: Crankshaft drive pulleys-except Premier and Monaco

  1. Remove the air cleaner assembly. Disconnect the fuel lines from the engine. Disconnect the accelerator cable from the throttle body.
  2.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Raise the front of the vehicle and support safely on jackstands. Drain the engine oil.
  2.  


CAUTION
Please refer to General Information & Maintenance in this information guide before discharging the compressor or disconnecting air conditioning lines. Damage to the air conditioning system or personal injury could result. Consult your local laws concerning refrigerant discharge and recycling. In many areas it may be illegal for anyone but a certified technician to service the A/C system. Always use an approved recovery station when discharging the air conditioning.

  1. Remove the drive belts, then loosen and remove the air conditioning compressor mounting bolts, if so equipped. Position the compressor aside and hang from the vehicle's frame using stiff wire or strong cord. DO NOT disconnect the air conditioning lines. Disconnect the exhaust pipes from the exhaust manifolds.
  2.  

  1. On automatic equipped cars, remove the transaxle inspection cover and matchmark the torque converter to the flexplate. Remove the torque converter bolts. Have an assistant hold the crankshaft with a large socket wrench on the front crankshaft nut to keep it from spinning while trying to loosen the torque converter mounting bolts. Attach a C-clamp on the bottom of the converter housing to prevent the torque converter from sliding out of the transaxle when removing the engine. On manual equipped cars, the engine will slide off of the transaxle with the clutch assembly still attached to the flywheel.
  2.  
  3. Remove the power steering pump mounting bolts (if so equipped) and set the pump aside, upright, with the fluid lines attached. Fasten it to the frame of the vehicle using stiff wire or strong cord.
  4.  
  5. Remove the lower transaxle-to-engine bolts. Disconnect and label the starter motor wiring and remove the starter motor from the engine.
  6.  
  7. Lower the vehicle. Unplug and label all electrical connectors, vacuum hoses and engine ground straps from the engine, alternator and fuel injection system.
  8.  
  9. Support the transaxle with a floor jack or equivalent. Attach an engine lifting device to the engine.
  10.  
  11. Remove the upper transaxle-to-engine bolts.
  12.  
  13. To separate the engine mounts from the insulators, mark the right insulator-to-right frame support and remove the mounting bolts. Remove the front engine mount through-bolt. Remove the left insulator through-bolt from inside the wheel housing. Remove the insulator bracket-to-transaxle bolts.
  14.  
  15. Lift and remove the engine from the vehicle.
  16.  

To install:
  1. Lower the engine into the engine compartment. On manual equipped vehicles, carefully slide the engine onto the transaxle center shaft. Align the engine mounts and install the bolts; do not tighten the bolts until all bolts have been installed. Tighten the bolts to the following torque specifications:
    1. Front engine support assembly-to-engine upper bolt-125 ft. lbs. (169 Nm).
    2.  
    3. Front engine support assembly-to-engine lower nuts-75 ft. lbs. (102 Nm).
    4.  
    5. Front engine support assembly-to-vehicle frame bolt and nut-40 ft. lbs. (54 Nm).
    6.  
    7. Right engine support assembly-to-engine lower yoke nut-75 ft. Lbs. (102 Nm).
    8.  
    9. Right engine support assembly-to-engine yoke bolt-100 ft. lbs. (133 Nm).
    10.  
    11. Right engine support assembly-to-vehicle frame bolts-50 ft. lbs. (68 Nm).
    12.  
    13. Left insulator-to-engine bolt-40 ft. lbs. (54 Nm).
    14.  
    15. Left insulator-to-left rail bolt-50 ft. lbs. (68 Nm).
    16.  
    17. Dampener weight-to-left rail-200 inch lbs. (23 Nm).
    18.  
    19. Left rail-to-vehicle frame bolts-50 ft. lbs. (68 Nm).
    20.  

  2.  
  3. Install the upper transaxle-to-engine mounting bolts and torque to 75 ft. lbs. (102 Nm). Remove the engine lifting fixture from the engine.
  4.  
  5. Raise the vehicle and support safely on jackstands.
  6.  
  7. On automatic equipped vehicles, remove the C-clamp from the converter housing. Align the converter marks, and install the torque converter bolts. Have an assistant once again hold the crankshaft while tightening the torque converter-to-flexplate bolts to 55 ft. lbs. (75 Nm). Install the transaxle inspection cover.
  8.  
  9. Connect the exhaust pipe to the exhaust manifold. Install the starter motor and connect the wiring.
  10.  
  11. Install the power steering pump and air conditioning compressor to the engine brackets. Install the drive belts and adjust the drive belt tension. Refer to General Information & Maintenance for drive belt adjusting procedures.
  12.  
  13. Lower the vehicle. Reconnect all vacuum hoses and electrical connections to the engine, including the ground strap.
  14.  
  15. Connect the fuel lines and accelerator cable.
  16.  
  17. Install the radiator and fan assembly, then connect the fan motor wiring. Connect the radiator hoses and refill the cooling system, making certain that the drain petcock valve is closed on the radiator.
  18.  
  19. Refill the engine with the proper oil to the correct level.
  20.  
  21. Install the hood and the bolts loosely, then align the matchmarks on the hood and tighten the hood-to-hinge bracket bolts. Connect the cables to the battery (positive cable first).
  22.  
  23. Start and run the engine until it reaches normal operating temperatures and check for leaks. Adjust the transaxle linkage, if necessary.
  24.  
  25. Road test the vehicle for proper operation.
  26.  

Premier and Monaco

See Figures 6 through 35

Removing and installing the engine/transaxle assembly can be a large job for the Monaco and Premier cars. According to the manufacturer aside mount hydraulic lift and cradle dolly will be needed. The entire front sub-frame/cradle assembly must be removed to extract the engine/transaxle assembly from the vehicle. We do NOT recommend lifting the body with pulleys or floor jacks off of the engine/transaxle assembly and rolling it back to expose the engine/transaxle. This could result in personal injury or severe component damage.

  1. Disconnect the battery negative (-) cable first, then disconnect the battery positive (+) cable.
  2.  
  3. Relieve fuel system pressure. For more details refer to Fuel System .
  4.  
  5. Drain the radiator. Refer to General Information & Maintenance for this procedure.
  6.  
  7. Remove the throttle body hose mounting bolts.
  8.  



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Fig. Fig. 6: Throttle body hose and electrical connections-Premier and Monaco



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Fig. Fig. 7: Hose connections at the air cleaner assembly-Premier and Monaco



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Fig. Fig. 8: Cruise control and accelerator cables-Premier and Monaco

  1. Remove the hose from the idle speed regulator. Loosen the hose clamp and remove the throttle body hose.
  2.  

During removal of the engine/transaxle assembly, always label any disconnected wires, vacuum lines, or hoses. Performing this will make installation much easier and save you from a possible headache.

  1. Disconnect the crankcase ventilation fresh air inlet hose and remove the evaporator canister hose at the air cleaner assembly.
  2.  
  3. Remove the air sensor vacuum hose at the air cleaner assembly.
  4.  
  5. Remove the distributor coil wire and lay it to the side.
  6.  
  7. Disconnect the cruise control cable and accelerator cable from the throttle arm.
  8.  
  9. Depress the holding tabs on the cruise control and accelerator cables and push them through the holding bracket. Then lay the cables off to the side of the engine compartment.
  10.  
  11. Disconnect the hot air tube at the air cleaner.
  12.  
  13. Disconnect the air cleaner retainer clips, then remove the air cleaner.
  14.  
  15. Remove the battery hold-down clamp, then carefully remove the battery from the vehicle. Set the battery aside.
  16.  
  17. Remove the fuel; tank filler cap to relieve the fuel tank pressure. Install the fuel tank filler cap.
  18.  
  19. Disconnect the grey fuel return tube from the fuel pressure regulator and the black fuel supply line from the fuel rail. Squeeze the retainer tabs and pull the connectors apart.
  20.  
  21. Disconnect the vacuum hoses from the Exhaust Gas Recirculation (EGR) solenoid, the Manifold Absolute Pressure (MAP) sensor, and the Hevac vacuum reservoir.
  22.  
  23. Loosen the bulkhead connector bolt and pull the bulkhead connector off. Lay the bulkhead connector on top of the engine.
  24.  



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Fig. Fig. 9: Hot air tube at the air cleaner assembly



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Fig. Fig. 10: Fuel tubes, regulator and fuel rail



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Fig. Fig. 11: EGR solenoid and vacuum hoses

  1. Disconnect the vacuum booster hose from the brake vacuum booster. Lay the hose on top of the engine.
  2.  
  3. Unplug the electrical connector and the heater hoses at the dash panel (firewall).
  4.  
  5. Disconnect the bottom hose from the coolant pressure bottle.
  6.  
  7. Disconnect the radiator hoses from the water pump and stow the hoses to the side.
  8.  
  9. Disconnect the engine damper from the engine bracket. Push the shock up against the cooling fan.
  10.  
  11. Open the door on the driver's side and remove the bottom instrument panel section under the steering wheel.
  12.  
  13. Disconnect the shifter cable from the arm on the steering column. Depress the tabs on the side cable housing and pull the cable through the holding bracket.
  14.  


WARNING
The vehicle must be raised on a side mount hoist. Do not support the vehicle by the lower control arms.

  1. Raise the vehicle.
  2.  
  3. Remove the splash shield below the alternator.
  4.  
  5. Unplug the knock sensor, the oil level sensor, the oil pressure sender and the alternator connectors.
  6.  
  7. Disconnect the alternator output wire and the wire harness clip from the back of the alternator. Stow the wire harness to the side of the engine compartment.
  8.  



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Fig. Fig. 12: MAP vacuum line, Hevac hose and bulkhead connector



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Fig. Fig. 13: Electrical connector and vacuum booster hose



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Fig. Fig. 14: Heater hoses and coolant pressure bottle hose

  1. To loosen the accessory drive belt, loosen the pivot bolt, the locking bolt and the adjusting bolt of the drive belt tensioner.
  2.  
  3. Loosen the power steering pump bolts and nuts until the bracket drops down.
  4.  
  5. Remove the stud bolt behind the front power steering bracket.
  6.  
  7. Remove the rear power steering pump bracket mounting bolts, if so equipped. Remove the power steering pump from the engine and temporarily hang it from the vehicle's frame with stiff wire or strong cord. Do not disconnect the power steering hoses.
  8.  
  9. Remove the power steering reservoir mounting bolts, if so equipped. Stow the reservoir in the driver's side of the engine compartment.
  10.  
  11. Lower the vehicle.
  12.  
  13. If equipped, remove the air conditioning compressor mounting bolts. Remove the A/C compressor and stow it in the passenger's side of the engine compartment by hanging it with strong wire or cord from the vehicle's frame.
  14.  
  15. Remove the front wheel center covers. Remove the wheel hub cover and the cotter pin holding the wheel hub nut in place.
  16.  
  17. Loosen the hub nuts on both sides of the vehicle.
  18.  
  19. Raise the vehicle up to a height where access to the bottom and top of the engine compartment can be gained.
  20.  
  21. Remove the front wheels.
  22.  
  23. Remove the brake calipers and disc pads (refer to Brakes ). Use wire to hang the calipers from the strut springs.
  24.  



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Fig. Fig. 15: Engine damper assembly



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Fig. Fig. 16: Shifter cable and steering column shifter arm


WARNING
The steering knuckle bolts are splined into the knuckle. Do not turn the bolts to loosen; instead loosen the nuts.

  1. Remove the steering knuckle to strut attaching bolt nuts on both sides of the vehicle.
  2.  


WARNING
Use a brass hammer to tap the steering knuckle bolts out. Do not use a steel hammer, as damage to the threads will occur.

  1. On both sides of the vehicle tap the top steering knuckle bolt out first. Pull the strut out, pivoting the steering knuckle on the lower bolt.
  2.  
  3. Tap the lower steering knuckle out and separate the steering knuckle from the strut.
  4.  
  5. Disconnect the battery negative cable and solenoid wire at the starter motor.
  6.  
  7. Remove the middle starter mounting bolt and disconnect the ground cable.
  8.  
  9. Remove the front sill shield by unscrewing the mounting bolts.
  10.  



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Fig. Fig. 17: When lifting the vehicle, use a side mounted swing arm hydraulic hoist



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Fig. Fig. 18: Alternator bolt and sensor locations



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Fig. Fig. 19: Power steering pump bracket



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Fig. Fig. 20: Air conditioner compressor bolt locations

  1. Unplug the oxygen (O 2 ) sensor connector.
  2.  
  3. Pull the grommet surrounding the shifter cable down. Grasp the shifter cable and pull it through the hole in the body.
  4.  
  5. Disconnect the catalytic converter from the Y-pipe.
  6.  
  7. Raise the vehicle high enough the the engine and transaxle will be able to be rolled out from under it.
  8.  
  9. Install the special attaching bolts (designed to hold the cradle onto the sub-frame assembly) into the cradle by pushing the large end of the channel iron into the hole in the cradle.
  10.  



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Fig. Fig. 21: Hang the brake caliper from the strut spring-Premier and Monaco

  1. Jiggle the bolt until the channel iron lays flat in the hole. Do the same with the other bolt.
  2.  
  3. Install the dolly to the cradle with the dolly wheels toward the rear of the vehicle. Tighten the nuts. This dolly will be used to roll the engine/transaxle assembly out from under the vehicle.
  4.  
  5. Lower the vehicle until the dolly rests on the floor.
  6.  
  7. Make sure that the dolly is completely resting on the floor, then, laying on a mechanic's creeper or on the floor, remove the four cradle-to-vehicle mounting bolts.
  8.  


WARNING
Ensure that all hoses, vacuum lines and wire harnesses are positioned so that they will not snag and catch when the vehicle is lifted off the engine.

  1. Slowly raise the vehicle off of the engine/transaxle assembly.
  2.  



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Fig. Fig. 22: Remove the steering knuckle from the strut



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Fig. Fig. 23: Remove the subframe shield from under the vehicle



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Fig. Fig. 24: Shifter cable and grommet



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Fig. Fig. 25: The special attaching bolts used with the cradle dolly

  1. Draw (or mark with masking tape) the outline of the dolly legs and the center line of the wheels on the floor. Once the dolly is repositioned under the vehicle, it can be correctly placed so that it aligns with the vehicle at installation.
  2.  
  3. To move the dolly, position a floor jack under the center of the front bar of the dolly. Raise the front of the dolly until the legs are approximately 1 in. (25mm) off the floor. Push the dolly/floor jack to the desired position.
  4.  
  5. Support the transaxle with brackets supplied with the cradle dolly.
  6.  
  7. Attach an overhead crane of an engine lift to the lifting brackets on the cylinder heads.
  8.  
  9. Loosen the engine mount-to-cradle stud nuts.
  10.  
  11. Remove the starter motor.
  12.  
  13. Remove the access cover bolt.
  14.  



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Fig. Fig. 26: Attach the dolly to the cradle with the dolly wheels toward the rear of the vehicle



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Fig. Fig. 27: Access cover, torque converter and road speed sensor locations



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Fig. Fig. 28: Oil cooler hoses and aligning stud nuts



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Fig. Fig. 29: Top transaxle mounting bolts

  1. Remove the torque converter bolts one at a time. Rotate the engine until all bolts are removed.
  2.  
  3. Remove the transaxle road speed sensor.
  4.  
  5. Disconnect the transaxle oil cooler hoses from the transaxle.
  6.  
  7. Disconnect the transaxle kickdown cable at the throttle body.
  8.  
  9. Remove the top transaxle mounting bolts and the lower nuts from the aligning studs.
  10.  
  11. Remove the engine from the transaxle.
  12.  



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Fig. Fig. 30: Cradle mounting bolts



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Fig. Fig. 31: Power steering pump assembly

To install:
  1. Prior to connecting the engine to the transaxle, ensure that the torque converter is pushed back completely into the pump.
  2.  
  3. Install the top transaxle mounting bolts and alignment stud nuts. Tighten the bolts and nuts to 48 ft. lbs. (65 Nm).
  4.  
  5. Install the transaxle road speed sensor.
  6.  
  7. Install and adjust the transaxle kickdown cable at the throttle body.
  8.  
  9. Connect the transaxle oil cooler hoses.
  10.  
  11. Install the torque converter-to-drive plate bolts. Tighten these bolts to 24 ft. lbs. (33 Nm).
  12.  
  13. Install the access cover.
  14.  
  15. Lower the engine into the cradle. Tighten the engine mount stud and nuts to 30 ft. lbs. (40 Nm).
  16.  
  17. Install the differential cover bolt. Tighten the bolt to 20 ft. lbs. (27 Nm).
  18.  
  19. Install the starter motor. Tighten the bolts to 30 ft. lbs. (42 Nm).
  20.  
  21. Disconnect the engine lift or overhead crane/hoist.
  22.  
  23. Position the engine/transaxle/cradle assembly under the vehicle. Align the dolly with the outline of the dolly legs and wheels drawn on the floor when the assembly was removed.
  24.  



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Fig. Fig. 32: Power steering pump front bracket



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Fig. Fig. 33: Upper front mounting bracket bolt



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Fig. Fig. 34: Alternator locking, adjusting, and pivot bolts


WARNING
Ensure that all hoses, vacuum lines and wire harnesses are positioned so that they will not snag and catch when the vehicle is lowered onto the cradle.

  1. Lower the vehicle onto the cradle. Stop when the vehicle just touches the cradle bolt pads.
  2.  
  3. Install the cradle mounting bolts. The cradle bolt has a rubber spacer and metal washer. They must be installed with the rubber spacer between the body and the washer. Tighten the bolts to 92 ft. lbs. (125 Nm).
  4.  
  5. Raise the vehicle halfway up.
  6.  
  7. Push the lower control arm down and reconnect the steering knuckle to the strut. Install the top bolt first. Then the lower bolt. The strut bolts are splined to the steering knuckles. Tighten the nuts, not the bolts. Tighten the nuts to 123 ft. lbs. (167 Nm).
  8.  
  9. Install the disk brake pads and calipers (refer to Brakes for this procedure).
  10.  
  11. Have an assistant apply pressure to the brake pedal to hold the hub in place, then tighten the hub nuts to 181 ft. lbs. (245 Nm).
  12.  
  13. Raise the vehicle the rest of the way up.
  14.  
  15. Remove the dolly from the cradle. Remove the special bolts from the cradle.
  16.  
  17. Connect the catalytic converter to the Y-pipe.
  18.  
  19. Plug the electrical connector back into the O 2 sensor.
  20.  
  21. Connect the starter wires and the battery negative cable to the starter motor.
  22.  
  23. Position the power steering pump against the engine. Finger-tighten the rear bracket mounting bolts.
  24.  
  25. Install the stud bolt through the timing cover and thread it into the rear bracket. Tighten the stud bolt to 30 ft. lbs. (40 Nm).
  26.  



Click image to see an enlarged view

Fig. Fig. 35: EGR solenoid and vacuum hoses-Premier and Monaco

  1. Tighten the rear mounting bolts to 20 ft. lbs. (27 Nm).
  2.  
  3. Pivot the power steering pump front bracket up over the stud bolt.
  4.  
  5. Thread the lower front mounting bolt in a couple of threads.
  6.  
  7. Start the nut on the stud. Finish tightening the lower front mounting bolt to 30 ft. lbs. (40 Nm).
  8.  
  9. Tighten the stud nut to 30 ft. lbs. (40 Nm).
  10.  
  11. Install the upper front mounting bolt. Tighten the bolt to 20 ft. lbs. (27 Nm).
  12.  
  13. Connect the alternator output wire, the alternator connector and the wire harness clip at the alternator.
  14.  
  15. Attach the oil pressure sender, the oil level sender, and the knock sensor electrical connectors to their respective sending units.
  16.  
  17. Position the splash shields in the wheelwells so that they hang straight down.
  18.  
  19. Install both front wheels and tighten the lug nuts to 63 ft. lbs. (85 Nm).
  20.  
  21. Push the transaxle shifter cable through the hole in the body and into the passenger's compartment. Position the grommet into the hole.
  22.  
  23. Lower the vehicle.
  24.  
  25. Install the air conditioning compressor on the valve cover. Tighten the bolts to 20 ft. lbs. (27 Nm).
  26.  
  27. Position the accessory drive belt on the pulleys. Be sure that the belt is routed correctly. Refer to General Information & Maintenance for this procedure.
  28.  
  29. Raise the vehicle.
  30.  
  31. Install a belt tension gauge on the accessory drive belt halfway between the air conditioning compressor and the alternator. On vehicles without air conditioning, install the gauge halfway between the water pump and the alternator.
  32.  
  33. Tighten the adjusting bolt until the correct belt tension is obtained (values a and b). If a new accessory drive belt is installed, it must be retightened after 7500 miles (12,000 km) of use (at which time it must be considered a used belt-do not retighten it to 180-200 lbs./800-889 N). The correct belt tension is:
    1. New belt-180-200 lbs. (800-889 N).
    2.  
    3. Used belt-140-160 lbs. (622-712 N).
    4.  

  34.  
  35. Tighten the alternator pivot bolt to 37 ft. lbs. (50 Nm).
  36.  
  37. Tighten the alternator locking bolt to 20 ft. lbs. (27 Nm).
  38.  
  39. Install the splash shield under the alternator.
  40.  
  41. Lower the vehicle.
  42.  
  43. Connect the heater hoses at the dash panel.
  44.  
  45. Connect the coolant bottle lower hose.
  46.  
  47. Push the black fuel supply tube onto the fuel rail until an audible click is heard. Pull back to ensure that the connector is locked in place.
  48.  
  49. Push the grey fuel return tube onto the fuel pressure regulator until an audible click is heard. Pull back to ensure that the connector is locked in place.
  50.  
  51. Connect the MAP sensor vacuum hose and the Hevac vacuum reservoir hoses.
  52.  
  53. Install the bulkhead connector and secure with the bulkhead bolts. Connect the electrical harness plug at the dash panel.
  54.  
  55. Connect the EGR solenoid vacuum hoses.
  56.  
  57. Connect the front engine shock absorber to the engine bracket.
  58.  
  59. Install the upper and lower radiator hoses at the water pump.
  60.  
  61. Install the power steering reservoir to the engine.
  62.  
  63. Install the battery and battery hold-down bracket.
  64.  
  65. Install the air cleaner.
  66.  
  67. Install the air sensor vacuum hose at the air cleaner.
  68.  
  69. Route the coil wire through the clips on the air cleaner and install the distributor cap.
  70.  
  71. Connect the evaporator canister hose and the crankcase ventilation fresh air inlet hose at the air cleaner.
  72.  
  73. Connect the hot air tube to the air cleaner.
  74.  
  75. Connect the accelerator cable and cruise control cable tot he throttle arm.
  76.  
  77. Close the radiator drain.
  78.  
  79. Connect the vacuum booster hose to the brake vacuum booster.
  80.  
  81. Connect the transaxle shifter cable. Slide it through the holding bracket and attach it to the arm on the steering column. Install the section of instrument panel.
  82.  
  83. Install the throttle body cover.
  84.  
  85. If the engine oil was drained, refill the crankcase with clean oil.
  86.  
  87. Connect the battery positive (+) cable first, then connect the battery negative (-) cable.
  88.  
  89. Fill the cooling system.
  90.  
  91. Start the engine and allow it to warm up to normal operating temperature, then check for fluid leaks.
  92.  

 
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