Engine - Removal
REMOVAL - ENGINE - HEV
WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury Service Precautions
1. Perform the fuel system pressure release procedure Service and Repair
2. Perform the HEV high voltage power down procedure Battery System - High Voltage Power Down
3. Disconnect the 12 volt battery system ground isolation connector (1) and remove the connector from the electric vacuum pump bracket (2).
4. Remove the vacuum hose (3) from the electric vacuum pump.
5. Disconnect the electrical connector (4) from the electric vacuum pump.
NOTE: Before removal, observe the orientation of the two battery cables (3) to properly position during installation.
6. Lift the positive battery cable access cover (1) and remove the positive battery cable nut (2). Position the positive battery cables (3) aside for access.
7. Remove the battery cable junction block bolt (4) and position the battery cable junction block aside for access to remove the electric vacuum pump.
8. Disconnect the high voltage inter lock (HVIL) electrical connector (1).
9. Remove the clean air tube retaining bolt (3).
10. Remove the clean air tube (2).
11. Remove the center air cleaner trim cover (2) with a small screwdriver (1).
12. Disconnect the intake air temperature (IAT) sensor electrical connector (1).
13. Disconnect the brake booster hose and positive crankcase ventilation (PCV) hose.
14. Remove the center air cleaner fastener (2).
15. Slightly raise the front of the air cleaner housing (3) up off the throttle body.
16. Slide the air cleaner housing forward to remove the rear air cleaner housing pegs (2) from the grommets (1) on the rear of the intake manifold.
17. Remove the air cleaner housing from the vehicle.
18. Mark all nut and hinge attachment locations using a grease pencil or equivalent, to provide reference marks for installation.
19. Remove the top nuts (3) attaching the hood to the hinge and loosen the bottom nuts (3) until they can be removed by hand.
20. Remove the bottom nuts (3) and remove the hood (1) from the vehicle.
21. Remove the hood prop rod.
22. Remove the cowl grille (4), windshield wiper arms and cross-bar beam Cowl Panel Cover - Removal
23. Remove the HVAC air inlet baffle/plenum retaining clips (1) and remove the air inlet baffle (2).
24. Remove the HVAC air inlet duct retaining nuts (1) and remove air inlet duct (2).
25. Recover the refrigerant from the A/C system Refrigerant System Recovery
26. Remove the electric vacuum pump (2) Removal
WARNING: Do not remove the radiator pressure cap, cylinder block drain plugs or loosen the radiator draincock with the system hot and under pressure. Serious burns from coolant can occur.
27. Remove the radiator pressure cap.
28. Place the vehicle in neutral, raise and support the vehicle and drain the engine oil.
29. Remove the oil filter.
30. Loosen the radiator petcock (1) and completely drain the radiator.
31. Remove the traction power inverter module (TPIM) drain plug (2) and completely drain the TPIM cooling system.
32. Remove the hose clamps and disconnect the TPIM cooler extension lines.
33. Remove the hose clamp and disconnect the TPIM Cooling hose (1).
34. Disconnect the electrical connectors (2) and position the harness aside.
35. Remove the TPIM coolant pump mounting bolts (2).
36. Remove the TPIM coolant pump and bracket (1) from the vehicle.
37. Remove the cylinder block drain plugs (1) and completely drain the cooling system.
38. Using the disconnect tool 9546, disconnect the transmission fluid cooler lines (1) from the transmission cooler.
39. Reposition the lower radiator hose clamp (2) and disconnect the lower radiator hose at the radiator.
40. Disconnect the transmission fluid cooler lines from their retainers at the oil pan.
41. Using the disconnect tool 9546, disconnect the transmission fluid cooler lines (1) from the transmission fittings (2) and remove the transmission fluid cooler lines.
42. Disconnect the electrical connectors from the oil temperature sensor (1) and the oil pressure sensor (3).
43. Remove the ground cable retaining bolt/stud (2).
44. Disconnect the electrical connectors from the knock sensor (1) and the crankshaft position sensor (2) and position the harness aside.
45. Remove the ground cable bolt (1) located in front of the left engine mount and reposition the ground cable (2) aside.
46. Remove both front engine mount (1) through bolts (2) (left side shown, right side similar).
CAUTION: When servicing or replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor.
47. Disconnect the oxygen sensor electrical connectors (2).
48. Saturate all exhaust bolts and nuts with Mopar(R) Rust Penetrant. Allow 5 minutes for penetration.
49. Remove the exhaust pipe to manifold bolts (3) (left side shown, right side similar) and disconnect the front exhaust pipe/catalytic converter assembly (4) at the exhaust manifolds.
50. Remove the exhaust crossover clamp retaining bolt (1) and remove the left exhaust pipe/catalytic converter assembly (3).
51. Remove the four transmission auxiliary oil pump bolts (1) and position the auxiliary oil pump (2) aside and discard the gasket (2).
CAUTION: Failure to follow these instructions may result in a driveline vibration.
52. Remove the front propeller shaft Drive Shaft - Removal
53. Remove the steering rack to frame mounting bolts, and lower the steering rack enough to gain clearance for the engine structural dust cover removal Steering Gear - Removal
54. Remove the engine structural dust cover (2) Structural Dust Cover - Removal
55. Rotate the crankshaft in a clockwise direction and remove the transmission damper bolts (1) from the flexplate (2).
56. Remove the transmission (1) bell housing to engine block bolts (2).
57. Remove the three differential bracket bolts (1) at the differential.
58. Remove the differential bracket to engine block rear bolt (2).
59. Lower the vehicle.
60. Disconnect the electrical connectors from the EGR valve (1), throttle body (2) and the coolant temperature sensor (3) and reposition the electrical harness aside.
61. Remove the EGR valve routing tube (2) bolts and remove the routing tube.
62. Remove the upper radiator hose.
63. Remove the overflow tube.
64. Reposition the heater hose clamps (1,3) and disconnect the heater hoses.
65. Reposition the lower radiator hose clamp and remove the lower radiator hose (2).
66. Remove the traction power inverter module (TPIM) coolant recovery bottle TPIM Coolant Recovery Container - Removal
67. Remove the traction power inverter module (TPIM) (1) Traction Power Inverter Module - Removal
68. Remove the high voltage cable support bracket retaining nuts (1) located at the back of the right cylinder head.
69. Lift the high voltage cable out of the support bracket and position the high voltage cable aside.
70. Remove the push-pin retainers (1) and the upper condenser/radiator seal (2).
71. Disconnect the radiator fan electrical connector (1).
72. Disconnect the electrical harness (3) push-pin retainers (2) from the fan shroud.
73. Remove the upper radiator support retaining bolts (2) and remove the upper radiator support (3).
74. Remove the condenser and cooling fan as an assembly A/C Condenser - Removal
75. Remove the radiator, cooling fan and the transmission oil cooler as an assembly Engine Cooling Radiator - Removal Removal
NOTE: Aspen grille shown, Durango grille similar.
76. Remove the grille upper four retaining bolts (1).
77. Remove the grille lower four retaining bolts (2) and remove the grille (3).
78. Using a grease pencil or equivalent, mark hood latch position for installation alignment.
79. Remove the hood latch (4) mounting bolts (3) and position the hood latch aside.
80. Remove the radiator crossmember retaining bolts (2) and remove the crossmember (1).
81. Disconnect the fuel supply line quick connect fitting at the fuel rail (1) and plug the fuel supply line with a shipping cap to prevent spillage Service and Repair
NOTE: The factory fuel injection electrical harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If the harness was not tagged, note the electrical location noted during removal.
82. Disconnect the electrical connectors to all fuel injectors and position the fuel injector electrical harness aside.
83. Remove the main engine electrical harness support strap at the rear of the intake manifold and position harness aside.
84. Using the sequence shown, remove the intake manifold retaining bolts.
85. Slide the intake manifold forward and disconnect the manifold air pressure (MAP) sensor (1) connector located at the rear of the engine.
86. Remove the intake manifold.
87. Disconnect the oil control valve (OCV) electrical connector (2).
88. Remove the OCV fastener (1).
NOTE: To remove the oil control valve (OCV), the engine must be at room temperature.
89. Rotate the OCV to break the seal and remove the OCV.
90. Remove the two upper bell housing to engine block bolts.
91. Remove the right and left ground straps located at the back of both cylinder heads.
92. Disconnect the MDS electrical harness connector (1) located at the back of the left cylinder head and position the harness (2) aside.
NOTE: Do not use air tools to install the engine lift fixture (1) 8984A and engine lift fixture adapter 8984-Eagle.
93. Install the engine lift fixture (1) 8984A and engine lift fixture adapter 8984-Eagle (2).
94. Install the engine support fixture 8534B (3).
95. Using the engine support fixture, raise the engine several inches to gain access the differential bracket to engine block front bolt.
96. Raise and support the vehicle.
97. Remove the differential bracket to engine block front bolt (1) and remove the differential bracket (2).
CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment.
CAUTION: A small quantity of refrigerant oil may be lost from the A/C compressor when the A/C suction and discharge lines are disconnected. Prior to removing the A/C lines from the A/C compressor, it very important to place a small clean container below the compressor to capture any refrigerant oil that may leak from the compressor suction and discharge ports. Always measure the amount of refrigerant oil lost and replace with the same amount of fresh clean ND-11 POE refrigerant oil prior to recharging the A/C system. Never use PAG oil in an HEV model or operate the A/C system with an incorrect amount of oil in the system. Failure to follow this caution may result in serious damage to the HEV A/C system.
98. Disengage the grey Connector Position Assurance (CPA) latch (1) and disconnect the black Low Voltage (LV) connector (2) from the A/C compressor (6). Push down on the grey CPA and pull the LV connector straight out.
99. Disconnect the orange High Voltage (HV) connector (4) from the A/C compressor by moving the red tab (3) on the connector inboard towards the engine, so that the tab does not stick out of the side of the connector. Then insert a flat blade screwdriver into the slot (5) at the bottom of the HV connector to disengage the integral latch and pull the HV connector straight out.
100. Disconnect the orange HV cable from the retainer at the front of the engine and remove HV cable.
101. Remove the bolt that secures the suction line bracket (1) to the front of the engine.
102. Remove the nuts (3) that secure the A/C suction line (2) and the A/C discharge line (4) to the A/C compressor (5).
103. Disconnect the A/C suction and discharge lines from the A/C compressor and remove from vehicle.
104. Discard the O-ring seals and gaskets from A/C suction and discharge lines.
105. Install plugs or tape over the open refrigerant line fittings and the compressor ports.
106. Support the A/C compressor (3) and remove the three nuts (1) and studs (2) that secure the compressor to the engine.
107. Remove the A/C compressor (3) from the engine compartment A/C Compressor - Removal
108. Lower the vehicle.
109. Remove the engine support fixture 8534B and install a suitable engine hoist.
110. Separate the engine from the transmission and remove the engine from the vehicle.