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Home >> Chrysler >> 2009 >> Sebring Base, 2D Convertible, ED3 >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (2.7L Engine (Service Information)) >> Removal >> Engine Assembly

Engine Assembly

WARNING: This page is about a different variant/trim than selected.
Fig 1: AIR BOX COVER
GC0121537Courtesy of CHRYSLER LLC
1 - Inlet Hose
2 - IAT sensor
3 - Fresh Air Hose
  1. Perform the fuel pressure release procedure. Refer to Fuel System/Fuel Delivery - Standard Procedure .
  2. Disconnect and isolate the negative battery cable.
  3. Recover the A/C system refrigerant. Refer to Heating and Air Conditioning/Plumbing - Standard Procedure .
  4. Remove the throttle body air inlet hose and air cleaner body assembly. See Engine/Air Intake System/BODY, Air Cleaner - Removal .
    Fig 2: Identifying Harness Connectors & Nuts
    GC0121538Courtesy of CHRYSLER LLC
  5. Disconnect engine harness to main harness connectors (5) and (6).
  6. Disconnect engine harness connector C2 (4) and transmission harness connector C4 (3) from the PCM.
  7. Remove the nut (2) and black ground cable from the remote negative battery post.
  8. Remove the nut (1) and the red starter cable from the remote positive battery post.
    Fig 3: Locating Upper Intake Manifold
    GC0121539Courtesy of CHRYSLER LLC
  9. Remove the upper intake manifold (1). See Engine/Manifolds/MANIFOLD, Intake - Installation .
    Fig 4: Locating Fuel Supply Hose & Fuel Rail
    GC0121540Courtesy of CHRYSLER LLC
  10. Disconnect the fuel supply hose (2) from the fuel rail (1). Refer to Fuel System/Fuel Delivery/FITTING, Quick Connect - Standard Procedure .
    Fig 5: SHIFT CABLE FROM MANUAL LEVER
    GC0121541Courtesy of CHRYSLER LLC
  11. Disconnect the gearshift cable (1) from the manual valve lever (2).
    Fig 6: Downstream & Upstream Oxygen Sensors
    GC0121542Courtesy of CHRYSLER LLC
    1 - ENGINE HARNESS CONNECTOR FOR O2 SENSOR 1/1
    2 - ENGINE HARNESS CONNECTOR FOR O2 SENSOR 1/2
    3 - LOWER FRONT DOWNSTREAM O2 SENSOR 1/2
    4 - LEFT ENGINE SIDE CATALYTIC CONVERTER
    5 - UPPER FRONT UPSTREAM O2 SENSOR 1/1
  12. Disconnect the front downstream oxygen sensor (3) from the engine wiring harness connector (2).
  13. Disconnect the front upstream oxygen sensor (5) from the engine wiring harness connector (1).
    Fig 7: Locating Cooling Fan Module, Screws, Retainers & Connectors
    GC0121543Courtesy of CHRYSLER LLC
  14. Disconnect the fan motor electrical connectors (4).
  15. Disengage three wire harness retainers (3) and the wire harness connector (5) from the cooling fan module (2).
  16. Remove five screws (1) retaining the wire harness to the upper core support.
  17. Disengage the two upper retainers and remove the cooling fan module (2) from the radiator.
    Fig 8: GENERATOR BATTERY CABLE
    GC0120977Courtesy of CHRYSLER LLC
  18. Remove the generator B+ terminal and field connection.
    Fig 9: Identifying Oil Dipstick Tube & Bolt
    GC0121544Courtesy of CHRYSLER LLC
  19. Remove the bolt (1) and the engine oil dipstick and tube (2).
    Fig 10: A/C Compressor-Refrigerant Lines
    GC0082736Courtesy of CHRYSLER LLC
  20. Disconnect the engine wire harness (1) from the A/C compressor connector (2).
  21. Remove the nut (4) that secures the A/C suction line (6) to the A/C compressor (3).
  22. Disconnect the A/C suction line from the A/C compressor and remove and discard the O-ring seals and gaskets.
  23. Install plugs in, or tape over the A/C suction line and A/C compressor fittings.
    Fig 11: Discharge Line To Jumper
    GC0121545Courtesy of CHRYSLER LLC
  24. Disconnect the wire harness connector (1) from the A/C pressure transducer (6) located near the right side of the radiator (5).
  25. Remove the nut (3) that secures the A/C discharge line to the discharge jumper line (4).
  26. Disconnect the A/C discharge line from the jumper line and remove and discard the O-ring seal and gasket.
  27. Install plugs in, or tape over the discharge and jumper line fittings.
    Fig 12: Belly Pan
    GC0121546Courtesy of CHRYSLER LLC
  28. Raise and support the vehicle on a hoist. Refer to Vehicle Quick Reference/Hoisting - Standard Procedure .
  29. Remove the belly pan (2), if equipped.
  30. Drain the engine oil. See Engine/Lubrication/OIL - Standard Procedure .
    Fig 13: TIRE AND WHEEL MOUNTING
    GC0082325Courtesy of CHRYSLER LLC
  31. Remove the front tire and wheel assemblies. Refer to Tires and Wheels - Removal .
    Fig 14: LOWER SPLASH SHIELD
    GC0121547Courtesy of CHRYSLER LLC
  32. Remove the left and right lower frame splash shields (2).
    Fig 15: LOWER FASCIA
    GC0121548Courtesy of CHRYSLER LLC
  33. Remove the closeout panel (1) from the fascia (3). Refer to Frame and Bumpers/Bumpers/FASCIA, Front Lower - Removal .
  34. Drain the cooling system. Refer to Cooling - Standard Procedure .
    Fig 16: HUB NUT
    GC0121549Courtesy of CHRYSLER LLC
  35. Remove both axle shafts (2). Refer to Differential and Driveline/Half Shaft - Removal .
    Fig 17: FRONT SPLASH SHIELDS
    GC0121550Courtesy of CHRYSLER LLC
  36. Remove left and right splash shields (2). Refer to Body/Exterior/SHIELD, Splash - Removal .
    Fig 18: FORE/AFT CROSSMEMBER 2
    GC0121551Courtesy of CHRYSLER LLC
  37. Remove the fore/aft cross-member (4). Refer to Frame and Bumpers/Frame/CROSSMEMBER - Removal .
    Fig 19: Accessory Drive Belt System - 2.7L
    GC0121552Courtesy of CHRYSLER LLC
    1 - GENERATOR
    2 - IDLER/TENSIONER
  38. Remove the accessory drive belt (2). Refer to Cooling/Accessory Drive/BELT, Serpentine - Removal .
    Fig 20: STRETCH TO FIT POWER STEERING BELT REMOVAL
    GC0121553Courtesy of CHRYSLER LLC
    1 - POWER STEERING PULLEY
    2 - STRETCH TO FIT POWER STEERING BELT
  39. Remove the power steering belt (2). Refer to Cooling/Accessory Drive/BELT, Serpentine - Removal .
    Fig 21: FRONT PUMP MOUNTING BRACKET BOLTS - 2.7L
    GC0121554Courtesy of CHRYSLER LLC
  40. Remove the power steering pump mounting bracket bolt (1) near the pump pulley.
    Fig 22: REAR PUMP MOUNTING BRACKET BOLTS - 2.7L
    GC0121555Courtesy of CHRYSLER LLC
  41. Do not  disconnect the power steering lines from the pump. Remove the two power steering pump mounting bracket bolts (2) behind the pump on the back of the engine and reposition the power steering pump and bracket assembly (1).
    Fig 23: Crossunder Pipe
    GC0121556Courtesy of CHRYSLER LLC
  42. Remove the crossunder pipe (3). Refer to Exhaust System/PIPE, Exhaust - Removal .
    Fig 24: Identifying Heater Return Hose & Lower Radiator Hose
    GC0121557Courtesy of CHRYSLER LLC
  43. Disconnect the heater return hose (1) from the pipe connection at right front frame rail area.
  44. Remove the lower radiator hose (2).
    Fig 25: Removing/Installing A/C Compressor
    GC0082737Courtesy of CHRYSLER LLC
  45. Support the A/C compressor (1) and remove the three bolts (2) that secure the compressor to the engine and remove the compressor with the discharge line attached.
    Fig 26: GENERATOR
    GC0120978Courtesy of CHRYSLER LLC
  46. Remove the three generator mounting bolts and remove the generator.
    Fig 27: Identifying Upper Radiator Hose, Heater Hose, Power Steering Reservoir, Connectors & Screw
    GC0121558Courtesy of CHRYSLER LLC
  47. Lower the vehicle.
  48. Remove the upper radiator hose (5) from the coolant outlet connector (4).
  49. Remove the heater hose (3) from the coolant outlet connector (4).
  50. Remove the mounting screw (1) and reposition the power steering reservoir (2).
    Fig 28: COOLANT RECOVERY CONTAINER - PRESSURE SYSTEM
    GC0120878Courtesy of CHRYSLER LLC
  51. Disconnect the return hose (2) from the coolant recovery container (4).
  52. Remove two fasteners (1) and lift the coolant recovery container (4).
  53. Disconnect the coolant recovery container hose (3) and remove the coolant recovery container (4).
    Fig 29: FRONT MANIVERTER HEAT SHIELD
    GC0121559Courtesy of CHRYSLER LLC
  54. Remove the front upper maniverter heat shield fasteners (1) and remove the heat shield (2).
    Fig 30: Front Exhaust Maniverter & Gasket
    GC0121560Courtesy of CHRYSLER LLC
  55. Remove the front exhaust maniverter attaching bolts (1), front maniverter (2) and gasket (3).
    Fig 31: 2.7L LOWER EGR TUBE
    GC0121561Courtesy of CHRYSLER LLC
  56. Remove the lower EGR tube (2). Refer to Emissions Control/Exhaust Gas Recirculation/TUBE, Exhaust Gas Recirculation (EGR) - Removal .
    Fig 32: Identifying Intermediate Shaft, Heat Shield & Bolts
    GC0120803Courtesy of CHRYSLER LLC
  57. Raise and support the vehicle.
  58. Remove the heat shield bolts (2) and the heat shield (3).
  59. Remove the intermediate shaft bolts (1) and (5) and remove the intermediate shaft (4).
    Fig 33: Downstream & Upstream Oxygen Sensors
    GC0121562Courtesy of CHRYSLER LLC
    1 - ENGINE HARNESS CONNECTOR FOR O2 SENSOR 2/1
    2 - UPPER REAR UPSTREAM O2 SENSOR 2/1
    3 - LOWER REAR DOWNSTREAM O2 SENSOR 2/2
    4 - RIGHT ENGINE SIDE CATALYTIC CONVERTER
    5 - ENGINE HARNESS CONNECTOR FOR O2 SENSOR 2/2
  60. Disconnect the rear downstream oxygen sensor (3) from the engine wiring harness connector (5).
  61. Disconnect the rear upstream oxygen sensor (2) from the engine wiring harness connector (1).
    Fig 34: Rear Maniverter Heat Shield
    GC0121563Courtesy of CHRYSLER LLC
  62. Remove the fasteners (1 and 2) and the rear maniverter heat shield (3).
    Fig 35: Rear Maniverter, Fasteners & Gasket
    GC0121564Courtesy of CHRYSLER LLC
  63. Remove the rear maniverter fasteners (1), rear maniverter (2) and rear maniverter gasket (3).
    Fig 36: DUST SHIELD
    GC0121565Courtesy of CHRYSLER LLC
  64. If equipped with the 62TE transmission, remove the bolt (1) and torque converter dust shield (2).
    Fig 37: Structural Collar & Bolts
    GC0121566Courtesy of CHRYSLER LLC
  65. If equipped with the 41TE transmission, remove the bolts (1) and (2) and the structural collar (3).
    Fig 38: TORQUE CONVERTER BOLTS
    GC0121567Courtesy of CHRYSLER LLC
  66. Mark the driveplate to torque converter position. Remove the driveplate bolts (1).
    Fig 39: Identifying Transaxle Bracket & Through Bolt
    GC0121568Courtesy of CHRYSLER LLC
  67. Remove the transaxle bracket to isolator through bolt (1).
  68. Remove the transaxle bracket bolt (3).
    Fig 40: Identifying Rear Mount Bracket-To-Transaxle Case Bolts
    GC0121569Courtesy of CHRYSLER LLC
  69. Lower the vehicle.
  70. Disconnect the oil cooler lines from the transaxle. Plug the lines and fittings to prevent debris from entering the transaxle or cooler circuit. Refer to Cooling/Transmission - Standard Procedure .
  71. Remove the remaining three transaxle bracket bolts (1) and remove the transaxle bracket.
    Fig 41: Powertrain Dolly & Engine Support Cradle With Posts
    GC0121570Courtesy of CHRYSLER LLC
  72. Adjust the vehicle height to allow the Powertrain Dolly 6135 (2) and Engine Support Cradle 6710A (3) with Cradle Posts 6848 and Cradle Post Adapter 6848 to be installed under the vehicle.
    Fig 42: A/C Compressor Mounting Bracket, Cradle Post & Adapter
    GC0121571Courtesy of CHRYSLER LLC
  73. Place the Cradle Post Adapter 6848 (2) between the A/C compressor mounting bracket (1) and the cradle post (3).
  74. Loosen the cradle post mounts to allow movement for positioning to the A/C compressor mounting bracket, the front engine mounting bracket and the oil pan rail. Lower the vehicle and position the cradle until the engine is resting on the posts. Tighten the post mounts to the cradle frame to prevent movement when removing or installing engine/transaxle assembly.
    Fig 43: RIGHT MOUNT V6
    GC0121572Courtesy of CHRYSLER LLC
  75. Continue lowering the vehicle so that the weight of the engine and transmission ONLY is on the cradle.
  76. Remove the three right side engine mount bolts (1).
    Fig 44: LEFT MOUNT
    GC0121484Courtesy of CHRYSLER LLC
  77. Remove the two left side transaxle mount bolts (2).
    Fig 45: Powertrain Dolly & Engine Support Cradle With Posts
    GC0121570Courtesy of CHRYSLER LLC
  78. Secure the engine/transaxle assembly to the dolly/cradle with a safety strap (1). Slowly raise the vehicle in short length spans. Inspect at each interval for potential engine or transaxle contact to vehicle components. Move the cradle/dolly fixture as necessary to allow for removal clearance.
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