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Wednesday, April 11, 2012

Dodge VAN and Chrysler Town & Country Complete Engine removal procedure?

Its the Engine removal Chapter for Dodge Caravan and Chrysler Town and Country car models.

The 3.3L and 3.8L engine removal procedure:-----

The complete step by step procedure with required details and helpful diagrams:----

The procedure is as follows:----


Removal & Installation



3.3L & 3.8L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Drain the cooling system.
  3. Drain the engine oil.
  4. Relieve the fuel system pressure.
  5. Recover the A/C refrigerant.
  6. Remove or disconnect the following:

    Battery and tray
    Air cleaner and hoses
    Fuel line from the rail
    Wiper module
  7. Block off the heater hoses to the rear system by using pinch off pliers, if equipped.
    NOTE
    When the transaxle lines are removed from the fittings at the transaxle damage to the inner wall of the hose will occur. To prevent leakage, cut the cooler hoses off flush at the transaxle fitting and use a service cooler hose splice kit upon installation.



    Heater hoses
    Radiator upper support crossmember
    Engine cooling fan
    Throttle body linkage
    Manifold Absolute Pressure (MAP) sensor connector
    Idle Air Control (IAC) valve connector
    Throttle Position (TPS) sensor connector
    Exhaust Gas Recirculation (EGR) transducer connector
    Vacuum lines from the throttle body, brake booster and speed control
    Wiring harness clip from the right side mount
    Power steering reservoir and set aside without disconnecting the lines
    Ground strap from the rear of the cylinder head
    Engine Coolant Temperature (ECT) sensor connector
    Ignition coil connectors
    Fuel injector connectors and clip from the bracket
    Camshaft (CMP) and Crankshaft (CKP) position sensor connectors
    A/C compressor electrical connectors and hoses. Cap the lines to avoid system contamination.
    Radiator upper hose
    Electrical connector at the transaxle dipstick tube
    Transaxle dipstick tube and seal the opening to avoid system contamination



    Transaxle cooler lines, cut the lines flush at the transaxle fittings
    Transaxle shift linkage and electrical connectors
    Axle halfshafts
    Crossmember cradle plate
    Power Transfer Unit (PTO), if equipped
    Exhaust front pipe from the manifold
    Front motor mount and bracket
    Rear motor mount bracket
    Engine-to-transaxle struts
    Transaxle case cover
    Torque converter
    Power steering pressure hose clip bolt
    Knock sensor connector, if equipped
    Engine block heater connector, if equipped
    Drive belt splash shield
    Accessory drive belt
    Lower radiator hose
    A/C compressor
    Alternator
    Water pump pulley bolts and position the pulley between the pump and the housing
    Oil pressure switch connector
    Wiring harness clip from the dipstick tube
  8. Install adapter tools on the right side of the engine block as illustrated

    Power steering pump and set aside
  9. Raise the vehicle enough to position dolly 6135, cradle tool 6710 with posts 6848 and adapter tool 6909 under vehicle.
  10. Loosen the cradle posts to allow movement for proper positioning. Lower the vehicle and position the cradle/post mounts until the engine is resting on the posts and then tighten the mounts to the cradle frame to prevent mounts from moving when removing/installing the powertrain assembly.
  11. Attach safety straps around the engine-to-cradle assembly. Lower the vehicle so the weight of the powertrain assembly, not the vehicle are on the cradle.
  12. Remove or disconnect the following: 

    Engine right side mount-to-engine bolts
    Left mount through bolt 

    image
    Fig. Adapter tools 6912 and 8444 mounted on the block-3.3L and 3.8L engines


    image
    Fig. Position tool 6848 for use with adapters 8444 and 6912-3.3L and 3.8L engines
  13. Raise the vehicle away from the powertrain.
To install:
  1. Lower the vehicle over the powertrain.
  2. Align the engine and transmission mounts to their attaching points. Install and tighten the right mount and left transmission mounts as shown in the two accompanying illustrations.
  3. Remove the safety straps and the dolly and adapters.
  4. Install or connect the following:

    Power steering pump and pressure line

    Click image to see an enlarged view
    Fig. Exploded view of the front engine mounting-3.3L and 3.8L engines


    Click image to see an enlarged view
    Fig. Exploded view of the right side hydro-type engine mounting-3.3L and 3.8L engines


    Click image to see an enlarged view
    Fig. Exploded view of the rear engine mounting-3.3L and 3.8L engines


    Click image to see an enlarged view
    Fig. Exploded view of the left engine mounting-3.3L and 3.8L engines


    Click image to see an enlarged view
    Fig. Exploded view of the left engine mounting on models equipped with a 31TH transaxle-3.3L and 3.8L engines


    Click image to see an enlarged view
    Fig. Exploded view of the left engine mounting on models equipped with a 41TE transaxle-3.3L and 3.8L engines


    Click image to see an enlarged view
    Fig. Exploded view of the right engine mounting-3.3L and 3.8L engines
    Alternator
    Wiring harness clip to the dipstick tube
    Oil pressure switch connector
    A/C compressor
    Water pump pulley
    Lower radiator hose
    Accessory drive belt
    Drive belt splash shield
    Engine block heater connector, if equipped
    Knock sensor connector, if equipped
    Power steering pressure hose clip bolt
    Torque converter
    Transaxle case cover
    Engine-to-transaxle struts
    Rear motor mount bracket
    Front motor mount and bracket
    PTO, if equipped
    Axle halfshafts
    Exhaust front pipe to the manifold
    Crossmember cradle plate
    Transaxle shift linkage and electrical connectors
    Transaxle cooler lines using a splice kit
    Transaxle dipstick tube and
    Electrical connector at the transaxle dipstick tube
    A/C compressor electrical connectors and hoses
    CMP and CKP position sensor connectors
    Fuel injector connectors and clip to the bracket
    ECT sensor connector
    Ignition coil connectors
    Ground strap to the rear of the cylinder head
    Power steering reservoir
    Wiring harness clip to the right side mount
    Vacuum lines to the throttle body, brake booster and speed control
    EGR transducer connector
    TPS sensor connector
    IAC valve connector
    MAP sensor connector
    Throttle body linkage
    Engine cooling fan
    Radiator upper hose
    Heater hoses
    Radiator upper support crossmember
    Wiper module
    Fuel line to the rail
    Air cleaner and hoses
    Battery and tray
  5. Fill the cooling system.
  6. Fill the engine with clean oil.
  7. Recharge the A/C system.
  8. Start the engine and check for leaks.


These details will help.
Thanks.           
FOR MORE HELP GO TO: ---
Car repair guide?

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