Dodge Colt/Challenger/Conquest/Vista 1971-1989 Repair Guide

Engine

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REMOVAL & INSTALLATION



Rear Wheel Drive Models


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Fig. Fig. 1 When removing nuts, bolts and other parts, place them in a tray or other container



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Fig. Fig. 2 Rear wheel drive engine mounting; most models similar



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Fig. Fig. 3 View of the DOHC 1.6L engine



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Fig. Fig. 4 Engine Mounting Torques

The factory recommends removing the engine and transmission as a unit.

  1. Drain the cooling system. Open the radiator petcock and the engine drain plug.
  2.  


CAUTION
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 quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Disconnect and remove the battery.
  2.  
  3. Disconnect the coil, throttle positioner solenoid, fuel cut-off solenoid, alternator, starter, transmission switch, back-up light switch, and temperature and oil pressure gauge sending units.
  4.  


CAUTION
Please refer to 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. On cars with air conditioning, the refrigerant must be released from the system.
  2.  
  3. Remove all air cleaner hoses. Remove the wing nut (and snap clips) and the air cleaner top cover.
  4.  
  5. Remove the two retaining nuts and bracket and remove the air cleaner housing.
  6.  
  7. Disconnect the accelerator cable.
  8.  
  9. Remove and plug the heater hose.
  10.  
  11. Remove the exhaust manifold nuts and drop the pipe down and out of the way.
  12.  
  13. Disconnect and cap the fuel lines at the pump. On cars with fuel injection, see for the procedure necessary to bleed the pressure from the system before disconnecting the lines.
  14.  
  15. Disconnect the vacuum hose from the canister purge valve located on the passenger side firewall. Remove the purge hose which runs from the valve to the intake manifold.
  16.  
  17. Scribe a line around the hood hinges, then remove the hood. Place it away from the work area or it will invariably become scratched or dented.
  18.  
  19. Remove the grille, radiator cross panel, the radiator and condenser. Disconnect and plug the oil cooler lines on automatic transmission equipped cars.
  20.  
  21. Jack up the front of the car and support it on jackstands. Remove the splash shield.
  22.  
  23. Drain the engine oil and the transmission oil or fluid. Remove the driveshaft.
  24.  


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 you 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. Disconnect the speedometer cable and back-up switch wire. Remove the neutral switch wire on automatic cars.
  2.  
  3. On manual transmission cars: Disconnect the clutch cable from the clutch lever.
  4.  
  5. Remove the control rod and the cross shaft that are located under the transmission.
  6.  
  7. Unite and open the leather shift boot. Pull the rug back. Remove the four retaining bolts and remove the shift lever.
  8.  
  9. On automatic transmission cars: Disconnect the transmission control rod from the shift linkage.
  10.  
  11. On all transmission models: Attach the lifting device to the two engine brackets provided by the factory, one near the water neck at the front and the other on the passenger's side at the rear.
  12.  
  13. Raise the engine a slight amount and remove the retaining nuts on the side mounts and the rear crossmember mount.
  14.  
  15. Lift the engine out of the compartment by tilting it at approximately a 45° angle.
  16.  

To install:

  1. Check the condition of the engine mounts. There are three: left front, right front, and rear. If they are at all questionable, now is the time to replace them.
  2.  
  3. Installing the engine is basically a reverse of the removal procedure, noting the following:
  4.  
  5. Drape heavy rags over the rear of the cylinder head to prevent damaging the firewall when lowering the engine into place.
  6.  
  7. Tighten the two front mounts first, then the rear crossmember mount. All tightening torques are listed in the chart below.
  8.  
  9. Fill the cooling system, engine crankcase, and the transmission with the proper fluids.
  10.  
  11. Double check everything: fuel lines, coolant lines, electrical connections, and bolt torques. Then, and only then, start the engine and check for correct operation and leaks.
  12.  

Front Wheel Drive Models
EXCEPT 4-WD VISTA


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Fig. Fig. 5 Exploded view of the engine mounting and torque specifications-models through 1980



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Fig. Fig. 6 Common front wheel drive engine and manual transaxle mounting-1981-89 models



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Fig. Fig. 7 Common front wheel drive engine and automatic transaxle mounting-1981-89 models

The factory recommends that the engine and transaxle be removed as a unit.

  1. Scribe the hood hinge outline on the underside of the hood. Remove the hood. Disconnect the battery cables (ground cable first) remove battery hold-down and battery. Remove the battery tray.
  2.  
  3. Remove the air cleaner assembly. Disconnect the purge control vacuum hose from the purge valve. Remove the purge control valve mounting bracket. Remove the windshield washer reservoir, radiator tank and carbon canister.
  4.  
  5. Drain the coolant from the radiator. Remove the radiator assembly with the electric cooling fan attached. Be sure to disconnect the fan wiring harness and the transmission cooler lines (if equipped).
  6.  


CAUTION
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 quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Disconnect the following cables, hoses and wires from the engine and transaxle: Clutch, Accelerator, Speedometer, Heater hose, Fuel lines, PCV vacuum line. High altitude compensator vacuum hose (Calif. Models), Bowl vent valve purge hose (U.S.A. Models), Inhibitor switch (Auto Trans), Control Cable (Auto Trans), Starter, Engine Ground Cable, Alternator, Water Temperature, Ignition Coil, Water Temperature Sensor, Back-up Light (Man. Trans), Oil Pressure Wires, and the ISC cable on fuel injected cars.
  2.  
  3. Remove the ignition coil. The next step will be to jack up the car. Before you do this, look around and make sure all wires and hoses are disconnected.
  4.  
  5. Jack up the front of the car after you block the rear wheels. Support the car on jackstands. Remove the splash shield (if equipped).
  6.  
  7. Drain the lubricant out of the transaxle, and drain the engine oil.
  8.  


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 you 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 right and left halfshafts from the transaxle and support them with wire. Plug the transaxle case holes so dirt cannot enter.
  2.  

The driveshaft retainer circlip ring should be replaced whenever the shaft is removed.

  1. Disconnect the assist rod and the control rod from the transaxle. If the car is equipped with a range selector, disconnect the selector cable.
  2.  
  3. Remove the mounting bolts/bolt from the front and rear roll control rods.
  4.  
  5. Disconnect the exhaust pipe from the engine and secure it with wire.
  6.  
  7. Loosen the engine and transaxle mounting bracket nuts. On turbocharged engines, disconnect the oil cooler tube.
  8.  
  9. Lower the car.
  10.  
  11. Attach a lifting device and shop crane or chain hoist to the engine. Remove the engine and transaxle mounting nuts and bolts.
  12.  
  13. Make sure the rear roll control rod is disconnected. Lift the engine and transaxle from the car. Make sure the transaxle does not hit the battery bracket when the engine and transaxle are lifted.
  14.  

To install:

  1. Lower the engine and transaxle carefully into position and loosely install the mounting bolts. Temporarily tighten the front and rear roll control rods mounting bolts. Lower the full weight of the engine and transaxle onto the mounts and tighten the nuts and bolts. Loosen and retighten the roll control rods.
  2.  
  3. Install the rest of the engine controls, lines and components. Make sure all cables, hoses and wires are connected. Fill the radiator with coolant, the transaxle with lubricant, and the engine with oil. Adjust the clutch cable and accelerator cable. Adjust the transaxle control rod. Take another check on everything you have done, start the engine and check for leaks.
  4.  

4-WD VISTA
  1. Scribe the hood hinge outlines on the underside of the hood. Remove the hood. Remove the battery, battery tray and bracket.
  2.  
  3. Disconnect the engine oil pressure switch and power steering pump connectors.
  4.  
  5. Disconnect the alternator harness.
  6.  
  7. Remove the air cleaner.
  8.  
  9. Remove the high tension cable from the distributor.
  10.  
  11. Disconnect the engine ground wire at the firewall.
  12.  
  13. Remove the windshield washer bottle.
  14.  
  15. Disconnect the brake booster vacuum hose.
  16.  
  17. Disconnect and tag all other vacuum lines connected to the engine.
  18.  
  19. Drain the coolant.
  20.  


CAUTION
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 quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the coolant reservoir tank.
  2.  
  3. Remove the radiator.
  4.  
  5. Disconnect the heater hoses at the engine.
  6.  
  7. Disconnect the accelerator cable.
  8.  
  9. Disconnect the speed control cable.
  10.  
  11. Disconnect the speedometer cable at the transaxle.
  12.  


CAUTION
Please refer to 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. If the car is equipped with air conditioning, the system must be bled.
  2.  
  3. Disconnect the hoses at the air conditioning compressor and cap all openings immediately.
  4.  
  5. Disconnect the hoses at the power steering pump.
  6.  
  7. On fuel injected models, discharge the fuel system pressure. Disconnect the fuel return hose, then the fuel inlet hose, at the carburetor or fuel rail.
  8.  
  9. Disconnect the shift control cables at the transaxle.
  10.  
  11. Raise and support the car on jackstands.
  12.  
  13. Remove the lower cover and skid plate.
  14.  
  15. Drain the transaxle and transfer case.
  16.  
  17. Disconnect the oxygen sensor, and disconnect the exhaust pipe from the manifold.
  18.  
  19. Remove the driveshaft to the rear wheels.
  20.  
  21. Remove the clutch slave cylinder.
  22.  
  23. Disconnect the halfshafts at the transaxle.
  24.  
  25. Remove the transfer case extension stopper bracket.
  26.  

The two top stopper bracket bolts are easier to get at from the engine compartment, using a T-type box wrench.

  1. Lower the vehicle to the ground.
  2.  
  3. Remove the nuts only, from the engine mount-to-body bracket.
  4.  
  5. Remove the range select control valves from the transaxle insulator bracket.
  6.  
  7. Remove the nut only, from the transaxle mounting insulator.
  8.  
  9. Remove the front roll insulator nut.
  10.  
  11. Remove the heat shield attaching bolt.
  12.  
  13. Remove the rear insulator-to-engine nut.
  14.  
  15. Remove the grille and valance panel.
  16.  
  17. Remove the A/C condenser.
  18.  
  19. Take up the weight of the engine with a shop crane attached to the lifting eyes.
  20.  
  21. Remove all the mounting bolts from which you previously removed the nuts.
  22.  
  23. Double check that you have disconnected all wiring, hoses and cables from the engine, transaxle and transfer case. Move the assembly forward slightly to a point at which it will clear the floorpan, and lift the whole assembly clear of the car.
  24.  
  25. Lower the engine and transaxle into position. Install the engine/transaxle mount attaching bolts and nuts loosely. Install the components in the reverse of removal. After the full weight of the engine/transaxle assembly lowered into position, tighten the mounting bolts and nuts. Observe the following torques:
  26.  



Transaxle stopper: 58 ft. lbs.
 
Engine-to-body bracket bolts: 47 ft. lbs.
 
Rear insulator: 29 ft. lbs.
 
Transaxle mount nuts: 58 ft. lbs.
 
Heat shield: 7 ft. lbs.
 
Front roll bracket nuts: 36 ft. lbs.
 

 
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