Chrysler Full-Size Vans 1989-1998 Repair Guide

Engine

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6, 7, 8 and 9

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 for each.
 
Always label 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, always make sure it is properly supported.
 
If it is necessary to disconnect the air conditioning system, have this service performed by a qualified MVAC 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.
 

  1. Properly relieve the fuel system pressure, as described in Fuel System .
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain and recycle the engine coolant.
  6.  


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the engine cover.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the oil dipstick tube.
  6.  
  7. Remove the front bumper.
  8.  
  9. Remove the grille and support brace.
  10.  
  11. Remove the cowl plenum-to-upper radiator supports.
  12.  
  13. Remove the coolant recovery and washer solvent bottles from the radiator support.
  14.  
  15. Remove the fan shroud.
  16.  
  17. Remove the fan, pulley and drive belts.
  18.  
  19. Disconnect the upper radiator hose.
  20.  
  21. Disconnect the lower radiator hose.
  22.  
  23. Label, disconnect, and plug the transmission cooler lines (if equipped).
  24.  
  25. Label and disconnect the heater hoses.
  26.  
  27. If so equipped, have the air conditioning system discharged by an MVAC certified automotive technician.
  28.  
  29. Disconnect the refrigerant lines at the condenser. Cap all openings at once to prevent contamination of the system.
  30.  
  31. Remove the radiator and condenser (if equipped) as an assembly.
  32.  
  33. Remove the air conditioning compressor (if equipped).
  34.  
  35. Remove the power steering pump from its bracket and position it out of the way. It is not necessary to remove the lines.
  36.  
  37. Label and disconnect the alternator wiring harness.
  38.  
  39. Remove the alternator.
  40.  
  41. Label and disconnect the hoses and remove the air pump (if equipped).
  42.  
  43. Label and disconnect all vacuum lines at the engine.
  44.  
  45. Disconnect and label the necessary engine electrical connectors.
  46.  
  47. Remove the throttle body assembly.
  48.  
  49. Disconnect the fuel line(s).
  50.  
  51. Check for any other lines, vacuum hoses, or wiring harnesses that must be disconnected. Label and disconnect them.
  52.  
  53. Raise and support the vehicle.
  54.  
  55. Drain and recycle the engine oil.
  56.  


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. Remove the engine oil filter.
  2.  
  3. Remove the engine-to-transmission struts.
  4.  
  5. Remove the oil pan.
  6.  
  7. Remove the oil pump and pickup tube assembly.
  8.  
  9. Remove the starter.
  10.  
  11. Disconnect the O2 sensor.
  12.  
  13. Remove the exhaust crossover pipe.
  14.  
  15. Remove the inspection plate or converter cover plate from the bell housing (automatic transmission). Remove the converter-to-flexplate bolts/nuts (automatic transmission).
  16.  
  17. Support the transmission on a floor jack or equivalent.
  18.  
  19. Remove the transmission-to-bell housing bolts, or the converter housing-to-engine bolts.
  20.  
  21. Install an engine lifting fixture.
  22.  
  23. Attach an engine crane and take up the weight of the engine.
  24.  
  25. Remove the nuts and washers from the engine mounts.
  26.  
  27. Remove the left exhaust manifold.
  28.  
  29. Loosen the engine-to-transmission junction.
  30.  
  31. Raise the engine and maneuver it through the front of the van. It may be necessary to raise the van slightly to keep the crane arm horizontal.
  32.  



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Fig. Fig. 1: Exploded view of a front engine mount



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Fig. Fig. 2: Exploded view of a rear engine support



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Fig. Fig. 3: The engine block should be drained if you plan on removing it for overhaul. There are drains on either side of the engine block



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Fig. Fig. 4: Accessory bracket mounted on an engine using a serpentine belt (removed)



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Fig. Fig. 5: One retaining bolt on the accessory bracket is hidden by the idler pulley; remove the pulley to access the bolt



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Fig. Fig. 6: The accessory bracket and bolts after removal from the engine. Note the location of each bolt, as they are different lengths



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Fig. Fig. 7: Attach the lifting device directly to the crane arm to remove the engine assembly



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Fig. Fig. 8: The A/C compressor, as mounted on the front of the engine



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Fig. Fig. 9: Remove the A/C compressor from its mount and support it; detaching the refrigerant lines is not necessary

To install:
  1. Installation is the reverse of removal.
  2.  
  3. Please note the following torque specifications:

    Engine mount nuts-75 ft. lbs. (102 Nm)
     
    Torque converter-to-drive plate-23 ft. lbs. (31 Nm)
     
    Converter Y-pipe-to-exhaust manifold-25 ft. lbs. (34 Nm)
     
    Starter motor-to-block-50 ft. lbs. (68 Nm)
     
    Exhaust manifold-to-head-25 ft. lbs. (34 Nm)
     
    Throttle body-to-intake manifold-200 inch lbs. (23 Nm)
     

  4.  

 
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