Engine Controls - Remove/install/overhaul: Removal & Installation Chrysler Concorde I

Removal (2.2L, 2.5L TBI & 3.0L)

1. Disconnect distributor pick-up wire(s) at distributor. Remove splash shield screws and splash shield. Rotate crankshaft until piston No. 1 is at TDC of compression stroke.
2. Ensure pointer on clutch housing is in-line with zero mark (TDC)on flywheel. Remove distributor cap screws and distributor cap. (Scheme 1)or (Scheme 2). Reference mark distributor rotor to distributor housing. Remove distributor bolt and distributor from engine.

Installation

1. Ensure piston No. 1 is still at TDC of compression stroke. Install distributor. Ensure distributor "O" ring is properly seated on engine block. To complete installation, reverse removal procedure.
2. Adjust ignition timing. See appropriate «ADJUSTMENTS»(ref-10828) article. Tighten distributor bolt.

Scheme 1

Scheme 2

Removal (3.3L & 3.5L)

Camshaft Position (CMP) sensor is located on front of timing case cover. Disconnect CMP sensor wiring harness connector. Loosen CMP sensor bolt and remove sensor. Removal force may be high due to "O" ring seal on sensor. DO NOT pull on sensor lead to remove sensor.

1. If old sensor is being reused, remove old paper spacer from sensor face. Install a new paper spacer to sensor face before installing sensor. Install NEW "O" ring on sensor. If installing a new sensor, ensure paper spacer is attached to sensor face and "O" ring is positioned correctly.
2. Apply oil to sensor "O" ring. Install CMP sensor by pushing down until paper spacer makes contact with cam timing gear. Hold sensor in position and tighten CMP sensor bolt to specification. See «TORQUE SPECIFICATIONS»(ref-10865-S36161828922000111000000) . Connect sensor wiring harness connector.

Crankshaft Position (CKP) sensor is located in transaxle housing. Disconnect CKP sensor wiring harness connector. Remove CKP sensor bolt and sensor.

1. If old sensor is to be reused, remove old paper spacer from sensor face. Install a new paper spacer to sensor face before installing sensor. If installing a new sensor, ensure paper spacer is attached to sensor face.
2. Install CKP sensor in transaxle. Push sensor down until paper spacer makes contact with drive plate. Hold sensor in position and tighten sensor bolt to specification. See TORQUE SPECIFICATIONS. Connect sensor wiring harness connector.

Removal (Except 3.3L & 3.5L)

Remove fuel tank. See FUEL TANK. Using a hammer and brass drift punch, carefully tap fuel pump lock ring counterclockwise. (Scheme 3) Remove lock ring, fuel pump and "O" ring seal from tank. Discard "O" ring and fuel inlet filter.

Clean fuel pump mating surfaces. Install new "O" ring and inlet fuel filter on pump. Install fuel pump and locking ring. Using a hammer and brass drift punch, drive lock ring around clockwise to lock pump in place. To complete installation, reverse removal procedure. Fill fuel tank. Turn ignition switch to ON position to pressurize fuel system. Check fuel system for leaks.

Scheme 3

Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect negative battery cable. Remove trunk liner. Remove 4 fuel pump access panel nuts. Remove access panel and gasket. Disconnect wiring harness connectors. Disconnect fuel hoses from fuel tank. Remove hose from pressure relief/rollover valve. Loosen fuel pump band clamp. Remove fuel pump.

1. Clean fuel pump mating surfaces. Install a NEW fuel pump gasket. Insert fuel pump into fuel tank. Ensure 2 fuel tank molded marks and fuel pump triangular mark are aligned. Seat fuel pump by pressing down on top of pump. Ensure gasket does not slip off-center. While holding fuel pump in seated position, place band clamp over lip of tank and edge of pump. Tighten band clamp to specification. See «TORQUE SPECIFICATIONS»(ref-10865-S36161828922000111000000) .
2. Install pressure relief/rollover valve hose. Connect fuel hoses to fuel tank. Connect wiring harness connectors. Turn ignition switch to ON position to pressurize fuel system. Check fuel system for leaks. To complete installation, reverse removal procedure.

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-10865-S20017948452000111000000) . Disconnect negative battery cable. Raise vehicle. Remove fuel drain cap, located on sending unit. Drain fuel from tank into an approved container.
2. Lower vehicle. Remove fuel filler tube-to-quarter panel screws. Raise vehicle. Remove right rear wheel, if necessary. Disconnect wiring harness connectors. Disconnect fuel hoses from fuel tank.
3. Support fuel tank. Loosen tank mounting straps and lower tank slightly. Remove hose from pressure relief/rollover valve. Carefully remove fuel filler tube from tank. Remove tank mounting straps and lower tank.

To install fuel tank, reverse removal procedure. Fill fuel tank. Turn ignition switch to ON position to pressurize fuel system. Check fuel system for leaks.

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-10865-S20017948452000111000000) . Disconnect negative battery cable. Remove fuel pump. See «FUEL PUMP»(ref-10865-S14035885372000111000000) . Using a portable fuel siphoning tank, drain fuel through fuel pump opening in fuel tank.
2. Raise vehicle. Remove rear wheels. Remove exhaust pipe hangers at rear of vehicle and at front of fuel tank. Reference mark fuel filler hose to filler tube and vent hose to vent tube. Remove splash shield from right rear wheelwell. Remove fuel filler hose and vent hose.
3. Disconnect sway bar from stabilizer links. Reference mark crossmember to frame rail. Remove crossmember bolts and crossmember. Place transmission jack under fuel tank. Remove and discard sway bar bracket bolts. Remove sway bar brackets, heat shield and fuel tank strap. Loosely reinstall sway bar brackets. Slightly lower front of fuel tank. Slide tank away from crossmember while pushing filler vent and fill tube over crossmember. Lower fuel tank.

1. Position fuel tank on transmission jack with heat shield and strap in place. Raise and position fuel tank over crossmember. Push filler vent and fill tube over crossmember. Rotate sway bar into position, and remove sway bar brackets.
2. Raise fuel tank into place. To complete installation, reverse removal procedure. Use NEW sway bar bracket bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-10865-S36161828922000111000000) . Lower vehicle. Fill fuel tank. Turn ignition switch to ON position to pressurize fuel system. Check fuel system for leaks. Check and adjust rear end alignment.

Removal (2.5L MFI & 3.0L)

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-10865-S20017948452000111000000). Disconnect negative battery cable. Remove hose between air cleaner and throttle body. Remove throttle cable.
2. Remove wiring harness connectors from throttle body. Remove vacuum hose harness from throttle body. Remove vacuum hoses from air intake plenum. Remove EGR tube flange from intake plenum (if equipped). Remove wiring harness connector from coolant temperature sensor.
3. Remove fuel hoses from fuel rail. Remove upper intake manifold assembly. Cover intake manifold openings during service. Remove vacuum hoses and fuel pressure regulator from fuel rail. Disconnect fuel injector wiring harness from engine wiring harness.
4. Remove fuel rail-to-intake manifold bolts. Remove fuel rail and injectors as an assembly. DO NOT damage "O" rings on fuel injectors. Cover injector ports with a suitable cover.
5. DO NOT remove fuel injectors from fuel rail until assembly is out of vehicle. Disconnect electrical connector from injector. Remove injector lock ring. (Scheme 4) Remove fuel injector from fuel rail.

To install, reverse removal procedure. Inspect fuel injector "O" ring for damage and replace as necessary. Apply light coating of clean engine oil on "O" rings. Install injector(s). Tighten bolts to specification. See TORQUE SPECIFICATIONS . Turn ignition switch to ON position to pressurize fuel system. Check fuel system for leaks.

Scheme 4

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-10865-S20017948452000111000000). Disconnect negative battery cable. Remove air cleaner assembly and air duct. Remove throttle and cruise control cables from throttle body.
2. Remove all interfering hoses and electrical connectors. Remove EGR tube screws and EGR at intake manifold plenum. Remove intake manifold plenum bolts, and lift intake manifold plenum from engine. Cover intake manifold holes during service. Remove fuel supply hose and fuel return tube at rear of intake manifold. Remove fuel tube clamp screws, and separate fuel tubes from bracket.
3. Rotate injectors toward center of engine. Tag injector connectors with appropriate cylinder number. Disconnect electrical connector from injector. Remove fuel rail bolts and lift fuel rail straight up. On 3.3L, remove fuel injector retaining clip and injector. (Scheme 4) On 3.5L, remove injector clamp screw and remove clamp. Reinstall clamp screw finger-tight. Using a flat-head screwdriver, pry fuel injector out of fuel rail. Remove clamp screw. On all models, cover fuel injector holes during service.

Apply a thin coat of engine oil to "O" rings on fuel injectors. Install injector in fuel rail cup. Install fuel injector retaining clip or clamp. On 3.5L, line up notch on injector with tab on injector rail. On all models, reverse removal procedure to complete installation. Tighten all components to specification. See TORQUE SPECIFICATIONS .

Removal (2.2L & 2.5L TBI)

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-10865-S20017948452000111000000) . Disconnect negative battery cable. Remove air cleaner assembly. Remove Torx screw holding injector cap.
2. Using 2 small screwdrivers, remove injector cap. Place small screwdriver in hole on front of electrical connector, and gently pry injector from throttle body. Ensure bottom injector "O" ring is removed with injector.

1. Install new "O" ring on injector cap. Injector will have "O" rings already installed. Apply a light coating of clean engine oil on "O" rings.
2. Place injector into throttle body assembly. Align injector wiring terminals with injector cap fastener hole. (Scheme 5) Install injector cap with locating notch aligned with locating lobe on injector.
3. Push down on injector cap to ensure proper sealing. Rotate injector cap and injector to align attachment hole. Install Torx screw. To complete installation, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-10865-S36161828922000111000000).

Scheme 5

Removal & Installation

1. O2 sensor is mounted in exhaust pipe just below exhaust header. O2 sensor is equipped with a permanent pigtail which must be protected from damage when the sensor is removed. Ensure sensor is free of contaminants. Avoid using cleaning solvents of any type.
2. Sensor may be difficult to remove when engine temperature is less than 120°F (48°C). Use Socket (C-4907) to remove sensor. Clean threads in exhaust manifold prior to installation of sensor.
3. If old sensor is being installed, coat threads on sensor with anti-seize compound. New sensors are packaged with anti-seize compound on threads. Tighten O2 sensor to specification. See «TORQUE SPECIFICATIONS»(ref-10865-S36161828922000111000000) .

Removal & Installation (TBI)

1. Remove air cleaner. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-10865-S20017948452000111000000) . Disconnect negative battery cable. Disconnect vacuum hoses and electrical connectors as necessary.
2. Remove throttle cable. Remove speed control and transmission kickdown cable (if equipped). Remove return spring (if equipped). Loosen fuel hose-to-valve cover clamp. Disconnect fuel supply and return hoses.
3. Remove throttle body screws. Remove throttle body. To install, reverse removal procedure. Tighten all bolts to specification. See «TORQUE SPECIFICATIONS»(ref-10865-S36161828922000111000000) .

Removal (MFI)

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-10865-S20017948452000111000000) . Disconnect negative battery cable. Remove air cleaner-to-throttle body screws. Disconnect wiring harness connectors, if necessary, from throttle body. Disconnect throttle and transaxle cables. CAUTION: Use only finger pressure to remove cruise control cable connector. If connector is damaged, cruise control servo and cable assembly must be replaced.
2. Using finger pressure, disconnect cruise control cable connector (if equipped). Remove throttle return spring (if equipped). Remove throttle body nuts, throttle body and gasket.

Ensure gasket mating surfaces are clean. Install new gasket and throttle body. To complete installation, reverse removal procedure. Tighten to specification. See TORQUE SPECIFICATIONS .

Disconnect negative battery cable. Remove air cleaner. Disconnect 3-pin connector at sensor. Remove screws attaching TPS to throttle body. Remove TPS. To install, reverse removal procedure. Tighten TPS screws to specification. See TORQUE SPECIFICATIONS .