2.7L V6 Engine: Removal & Installation Dodge Intrepid II

REMOVAL & INSTALLATION

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

Removal

Release fuel pressure. See FUEL PRESSURE RELEASE . Disconnect negative battery cable. Ensure area around fuel line and quick-connect fitting is clean. Place shop towel around fuel line. Squeeze retainer tabs together and pull quick-connect fitting off of fuel line. Retainer will stay on fuel line.

Installation

Ensure retainer is on quick-connect fitting or fuel line. Clean end of fuel line and retainer. Lubricate end of fuel line with 30W engine oil. Insert fuel line into disconnect fitting until retainer seats and a click is heard. To ensure proper fuel line connection, pull on fuel line and fitting.

Note. It is not necessary to discharge air conditioning system when removing radiator.

1. Disconnect negative cable from remote jumper terminal.
2. Drain cooling system.
3. Remove upper radiator crossmember.
4. Remove hose clamps and hose from radiator.
5. Disconnect transmission hoses from cooler and plug off.
6. Disconnect engine oil cooler lines (if equipped).
7. Disconnect the fan electrical connector.
8. Remove fan module.
9. Remove the A/C condenser attaching screws located at the front of the radiator.
10. Remove fastener attaching transmission cooler line bracket to left side of radiator.
11. Lift condenser upward, only enough to clear upper mounting clips; allow condenser to rest on lower radiator crossmember.
12. Radiator can now be lifted free from engine compartment.

1. Slide radiator down into position. Seat the radiator assembly lower rubber isolators in the mounting holes provided in lower radiator support.
2. Attach A/C condenser to mounting clips on radiator. Install mounting screws. See «TORQUE SPECIFICATIONS»(ref-9330-S05092372272000101800000) .
3. Connect lower radiator hose and clamp.
4. Install transmission cooler line bracket and attaching fastener. Connect automatic transmission hoses.
5. Install fan module.
6. Connect fan motor electrical connector.
7. Connect engine oil cooler lines (if equipped).
8. Install upper radiator hose. Align hose so it does not interfere with the accessory drive belt or engine. Position hose clamp so it will not interfere with the hood liner.
9. Install upper radiator support crossmember.
10. Connect negative cable to remote jumper terminal.
11. Refill cooling system.
12. Operate engine until it reaches normal operating temperature. Check cooling system and automatic transmission for correct fluid levels.

1. Disconnect negative battery cable from remote jumper terminal located at right strut tower. Mark hood at hinges, and remove hood. Drain cooling system. Cover drive belts and/or pulleys to prevent contact with coolant. If coolant contacts belts and/or pulleys, flush both with clean water.
2. Open radiator drain located at lower right side of radiator. DO NOT use pliers to open radiator drain. Remove coolant pressure bottle cap and open air bleed valve located on water outlet connector at front of engine. see scheme 2 Remove cylinder block drain plugs located below each exhaust manifold.
3. Remove wiper arms. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-9330-S26864618462000101800000). Disconnect fuel lines. See «FUEL LINE QUICK-CONNECT FITTING»(ref-9330-S10399366452000101800000). Remove cowl covers and cowl support.
4. Remove air cleaner assembly. Remove upper radiator crossmember. Disconnect hood release cable from hood latch. Disconnect cooling fan assembly connector and remove cooling fan assembly.
5. Disconnect upper radiator hose at engine. Disconnect lower radiator hose at radiator. Disconnect transaxle cooler lines at radiator. Remove fasteners attaching A/C condenser to radiator. Remove transaxle cooler lines support bracket, and attaching screw at left side of radiator. Remove radiator.
6. Remove drive belts. Remove power steering pump bolts, and set pump aside. Generator can be removed with engine assembly. Disconnect A/C compressor electrical connector. Remove A/C compressor bolts, and set compressor aside.
7. Loosen, remove and discard "V" band clamps at exhaust manifolds. Disconnect throttle and speed control cables. Disconnect coolant hoses at coolant pressure bottle. Disconnect heater hoses. Disconnect all vacuum lines and electrical connectors. Disconnect all engine ground straps.
8. Raise and support vehicle. Drain engine oil. Remove fasteners supporting catalytic converter down pipes at front and rear mounts. Remove structural collar bolts from oil pan and transaxle. (Scheme 20) Remove structural collar. Mark flexplate-to-torque converter position, and remove torque converter bolts. Disconnect both transaxle cooler line brackets from engine.
9. Remove starter. Remove crankshaft position sensor. Remove 2 lower transaxle-to-block bolts. Lower vehicle. Remove screws attaching fuel line and electrical harness to throttle body bracket. Remove electrical harness bracket, transaxle shift cable bracket, and throttle body support bracket from transaxle. CAUTION: Intake manifolds and valve covers are a composite design. Ensure intake manifolds and valve covers are not damaged when lifting engine from engine compartment.
10. Remove upper transaxle-to-engine block bolts. Remove right and left engine mount isolator-to-engine mount bracket fasteners. Remove camshaft position sensor from left cylinder head. Attach hoist to engine. Support transaxle with a floor jack. Hoist engine from engine compartment.

Note. Replace motor mounts only if they are leaking.

1. To install, reverse removal procedure. Install NEW exhaust manifold "V" band clamps.
2. DO NOT tighten engine mount bolts until all engine block-to-transaxle housing bolts have installed. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-9330-S05092372272000101800000) . Add 8.0 qts. (7.8L) of 50/50 mix of MOPAR® Extended Life Coolant (or equivalent) and distilled water. Bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-9330-S37112537302000101800000) .

Removal (Upper)

1. Disconnect negative battery cable from remote jumper terminal located at right strut tower. Remove air inlet resonator and tube. Remove throttle and speed control cable from throttle arm and bracket. Remove throttle cable bracket.
2. Disconnect Manifold Absolute Pressure (MAP) sensor, Throttle Position (TP) sensor, Intake Air Temperature (IAT) sensor, Idle Air Control (IAC) motor connectors and Manifold Tuning Valve (MTV), if equipped. Disconnect vapor purge, brake booster, speed control servo and PCV hoses.
3. Remove EGR tube. Loosen throttle body support bracket upper fastener. Remove upper manifold right and left side support brackets upper fasteners. Pull engine cover off of manifold. Remove upper manifold bolts and manifold.

Removal (Lower)

Release fuel pressure. See FUEL PRESSURE RELEASE . Remove upper intake manifold. Disconnect fuel injector connectors. Remove fuel supply hose from fuel rail. See FUEL LINE QUICK-CONNECT FITTING . Remove throttle body bracket-to-fuel rail bracket screw. Remove fuel rail bolts. Remove fuel rail and injectors as an assembly. Remove lower manifold bolts and manifold.

1. Clean and inspect mating surfaces. Gaskets can be reused if free from cuts or tears. On lower intake manifold, temporarily install bolt into No. 6 bolt hole of upper intake manifold. (Scheme 8) Finger tighten bolt 2-3 turns. This will position lower manifold. Ensure fuel injectors and wiring harnesses are out of way. Install lower manifold bolts.
2. Tighten lower manifold bolts to specification and in sequence. See «TORQUE SPECIFICATIONS»(ref-9330-S05092372272000101800000). (Scheme 9) Remove bolt from No. 6 bolt hole of upper intake manifold. To complete installation reverse removal procedures. Tighten upper manifold bolts to specification and in correct sequence. See «TORQUE SPECIFICATIONS»(ref-9330-S05092372272000101800000). (Scheme 8)

Scheme 8

Scheme 9

Removal (Right)

1. Disconnect negative battery cable from remote jumper terminal located at right strut tower. Remove upper intake manifold. See «INTAKE MANIFOLD»(ref-9330-S42245533222000101800000) . Remove battery cable housing tube-to-transaxle housing bolt.
2. Remove EGR valve bolts and EGR valve. Discard EGR gaskets. Disconnect O2S connector and remove O2S. Remove and discard "V" band clamp. Remove heat shield screws and heat shields. Remove exhaust manifold bolts and exhaust manifold.

Removal (Left)

1. Disconnect negative battery cable from remote jumper terminal located at right strut tower. Raise and support vehicle. Apply penetrating oil, and loosen band clamps at resonator connector. Support exhaust system with jack stand. Remove rubber isolators and exhaust system. Disconnect downstream O2S sensor connector and remove sensor.
2. Remove nut attaching left pipe to transaxle bracket. Remove "U" bracket and isolator from pipe hanger. Remove fastener attaching exhaust pipe front support to transaxle. CAUTION: DO NOT damage drive shaft boot when removing catalytic converter.
3. Remove catalytic converter. Remove transaxle dipstick housing bolt and rotate housing away from engine. Lower vehicle. Remove engine wiring harness from bracket. Remove engine wiring harness bracket from cylinder head.
4. Disconnect upstream O2S connector and remove sensor. Remove engine oil dipstick tube. Remove heat shield screws and heat shields. Remove exhaust manifold bolts and exhaust manifold.

Install NEW "V" band clamp. Install NEW "O" ring on engine oil dipstick tube. Install NEW EGR gaskets. Using NEW gasket, install manifold and tighten to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

1. Disconnect negative battery cable from remote jumper terminal located at right strut tower. Drain cooling system. Cover drive belts and/or pulleys to prevent contact with coolant. If coolant contacts belts and/or pulleys, flush both with clean water.
2. Open radiator drain located at lower right side of radiator. DO NOT use pliers to open radiator drain. Remove coolant pressure bottle cap, and open air bleed valve located on water outlet connector at front of engine. see scheme 2 Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-9330-S26864618462000101800000). Disconnect fuel lines. See «FUEL LINE QUICK-CONNECT FITTING»(ref-9330-S10399366452000101800000). CAUTION: Before removing crankshaft pulley, ensure A/C belt tensioner is not contacting crankshaft pulley.
3. Remove upper radiator crossmember. Disconnect fan assembly connector. Remove fan assembly. Remove drive belts. Hold crankshaft pulley and remove center bolt. Using a 3-jaw puller, remove crankshaft pulley.
4. Remove intake upper and lower manifold. See «INTAKE MANIFOLD»(ref-9330-S42245533222000101800000). Remove electrical and vacuum harness retaining clips from valve cover studs. Remove ignition coils. Remove valve covers. Remove power steering pump, and set aside. Remove drive belt tensioner pulley and bracket. Remove timing chain cover.
5. Remove water outlet connector. see scheme 2 Rotate crankshaft until crankshaft sprocket timing mark aligns with timing mark on oil pump housing. Remove primary timing chain. See «PRIMARY TIMING CHAIN & SPROCKETS»(ref-9330-S04023445582000101800000). Remove camshafts. See «CAMSHAFTS»(ref-9330-S29003563412000101800000). CAUTION: Ensure cylinder head bolts No. 9-11 are removed before attempting removal of cylinder head.
6. Remove cylinder head bolts in reverse sequence of installation. Remove bolts No. 9-11, then remove bolts No. 1-8. (Scheme 10) Remove cylinder heads.

1. Before installing head bolts, clean and lubricate threads with engine oil. Install head gasket over locating dowels. Ensure gasket is installed on correct side. Install cylinder head over dowels.
2. Tighten cylinder head bolts in correct sequence. (Scheme 10) Using 5-step torque turn method, tighten head bolts to specification as follows: First, tighten bolts No. 1-8 to 35 ft. lbs. (47 N.m). Second, tighten bolts No. 1-8 to 55 ft. lbs. (75 N.m). Third, tighten bolts No. 1-8 (again) to 55 ft. lbs. (75 N.m). Fourth, add 1/4 turn to bolts No. 1-8. DO NOT use a torque wrench for this step. Fifth, tighten bolts No. 9-11 to 21 ft. lbs. (28 N.m).

To complete installation, reverse removal procedure.

Scheme 10

Remove upper radiator crossmember. Disconnect fan assembly connector. Remove fan assembly. Remove drive belts. Remove crankshaft vibration damper. Hold crankshaft pulley and remove center bolt. Using a 3-jaw puller, remove crankshaft pulley. Use puller, remove front crankshaft oil seal. (Scheme 11)

Install crankshaft oil seal using installing sleeve, seal installer, and stud. (Scheme 12) To complete installation, reverse removal procedure.

Note. Ensure shaft seal surface is free of varnish, dirt and nicks. Polish with 400 grit paper if necessary.

Scheme 11

Scheme 12

Remove transaxle. See TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING. Remove drive plate. Pry out rear seal with screwdriver. DO NOT nick or scratch crankshaft flange seal surface or retainer bore.

Place seal pilot on crankshaft. Using seal driver, seal driver handle, and a plastic hammer, place seal over seal pilot and tap into place. Ensure seal is flush with housing surface. To complete installation, reverse removal procedure.

Remove crankshaft rear oil seal. See CRANKSHAFT OIL SEAL (REAR) . Remove oil pan. See OIL PAN . Remove rear crankshaft oil seal retainer bolts. Remove crankshaft oil seal retainer and gasket.

1. Clean mating surfaces and replace gasket as necessary. Install gasket and loosely assemble rear crankshaft oil seal retainer to engine block. Using oil pan bolts, attach crankshaft oil seal retainer aligner to oil pan rail. (Scheme 13) Ensure 2.7L mark, stamped on crankshaft oil seal retainer aligner, is facing engine block.
2. While pushing rear crankshaft oil seal retainer toward aligner, tighten crankshaft oil seal retainer bolts to specification. See «TORQUE SPECIFICATIONS»(ref-9330-S05092372272000101800000). Install crankshaft rear oil seal. To complete installation, reverse removal procedure.

Scheme 13

1. Remove upper intake manifold. See «INTAKE MANIFOLD»(ref-9330-S42245533222000101800000) . Remove electrical and vacuum harness retaining clips from valve cover studs. Remove ignition coils. Remove valve covers.
2. Using crankshaft, rotate camshaft until lobes are in a neutral position (little or no load to valves). Using spring compressor and spring compressor adaptor, compress valve spring to remove tension from rocker arm. Remove rocker arm assembly bolts. Remove rocker arms.

Rotate camshaft until lobes are in a neutral position (little or no load to valves). Ensure lash adjusters are at least partially full of oil. Install NEW retainer caps. Install lash adjusters. Install rocker arms. Ensure rocker arms are properly engaged into latch adjusters and valve tips. Tighten bolts to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

1. Remove primary timing chain. See «PRIMARY TIMING CHAIN & SPROCKETS»(ref-9330-S04023445582000101800000). Remove secondary chain tensioner mounting bolts. Slowly loosen camshaft bearing cap bolts in reverse order of installation. see scheme 16
2. Remove camshaft bearing caps and keep in order. Bearing caps have been marked with a number and a letter for location identification. Remove camshafts, secondary chain, and tensioner as an assembly. Remove tensioner and camshaft chain from camshaft.

1. Install secondary camshaft chain onto camshaft sprockets with plated links facing front of engine. Align plated links to dot on camshaft sprockets. (Scheme 14) If secondary chain tensioner is already in compressed and locked position, go to step 4).
2. On early build secondary camshaft chain tensioner, separate tensioner cylinder from tensioner housing. (Scheme 15) Drain oil from housing. Tensioner does not need to be disassembled. Using hand pressure, compress tensioner and insert a fabricated lock pin in lock pin holes. (Scheme 16)
3. On late build secondary camshaft chain tensioner, place tensioner into a soft-jaw vise. Slowly compress tensioner and insert a fabricated lock pin in lock pin holes. (Scheme 16)
4. Install compressed and locked secondary chain tensioner. Rotate camshafts so that plated links and dots are at 12 o'clock position. (Scheme 14) Install camshafts. Ensure rocker arms are correctly seated and in proper positions. Install camshaft bearing caps. Ensure bearing caps are installed in same position as removed. Tighten cam bearing cap bolts gradually, in sequence. see scheme 16
5. Install and tighten secondary chain tensioner bolts to 105 INCH lbs. (12 N.m). Remove locking pin form secondary chain tensioners. Using a dial indicator, measure camshaft end play.
6. Move camshaft to rear of its travel. Zero dial indicator. Move camshaft forward to limit of its travel and read dial indicator. See «CAMSHAFT»(ref-9330-S09925929222000101800000) table under ENGINE SPECIFICATIONS. (Scheme 17) Install primary timing chain. See «PRIMARY TIMING CHAIN & SPROCKETS»(ref-9330-S04023445582000101800000). To complete installation, reverse removal procedure.

Scheme 14

Scheme 15

Scheme 16

Scheme 17

1. Drain cooling system. Cover drive belts and/or pulleys to prevent contact with coolant. If coolant contacts belts and/or pulleys, flush both with clean water.
2. Open radiator drain located at lower right side of radiator. DO NOT use pliers to open radiator drain. Remove coolant pressure bottle cap and open air bleed valve located on water outlet connector at front of engine. see scheme 2 Remove primary timing chain. See «PRIMARY TIMING CHAIN & SPROCKETS»(ref-9330-S04023445582000101800000). Remove water pump bolts. Remove water pump and gasket.

Using NEW gasket, install water pump. To complete installation, reverse removal procedure. Tighten all bolts to specification. See TORQUE SPECIFICATIONS . Fill and bleed cooling system. See COOLING SYSTEM BLEEDING .

1. Disconnect negative cable from remote jumper terminal.
2. Drain cooling system.
3. Remove accessory drive belt for removal of the generator.
4. Raise vehicle on hoist.
5. Remove generator attaching bolts. Set generator aside for ease of access to thermostat.
6. Remove lower radiator and heater hoses from thermostat housing.
7. Remove thermostat housing bolts.
8. Remove thermostat and housing.

Note. Install thermostat with the bleed valve located at the 12 o'clock position.

1. Clean gasket sealing surfaces.
2. Install thermostat and gasket into the thermostat housing.
3. Install thermostat and housing to cylinder block. See «TORQUE SPECIFICATIONS»(ref-9330-S05092372272000101800000) .
4. Connect heater and lower radiator hoses. Install hose clamps.
5. Install generator and attaching bolts.
6. Lower vehicle.
7. Install accessory drive belt.
8. Refill cooling system.
9. Connect negative cable to remote jumper terminal.

Remove dipstick and dipstick housing. Raise and support vehicle. Drain engine oil and remove oil filter. Remove structural collar located between oil pan and transaxle housing. Remove oil pan bolts and nuts, and remove oil pan.

1. Ensure oil pan and mating surfaces are clean. Inspect oil pan and timing chain cover gaskets and replace as necessary. Apply a 1/8" bead of silicone rubber adhesive sealant to oil pan-to-timing chain cover mating surface. (Scheme 18)
2. Install oil pan gasket to engine block. Install oil pan. Install oil pan bolts and nuts finger tight (just tight enough to compress gasket's rubber seal). Install timing chain cover-to-pan bolts, and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-9330-S05092372272000101800000). Tighten oil pan bolts, and then oil pan nuts, to specification. (Scheme 19)
3. Install structural collar-to-oil pan vertical (position) bolts (No. 1) and tighten bolts to 10 INCH lbs. (1 N.m). (Scheme 20) Install structural collar-to-transaxle bolts (No. 2) and tighten bolts to 40 ft. lbs. (54 N.m).
4. Starting with center vertical (position) bolts (No. 1) and working outward, tighten bolts to 40 ft. lbs. (54 N.m). To complete installation, reverse removal procedure.

Scheme 18

Scheme 19

Scheme 20

Removal & Disassembly

1. Remove upper radiator crossmember. Disconnect fan assembly connector. Remove fan assembly. Remove drive belts. Hold crankshaft pulley and remove center bolt. Using a 3-jaw puller, remove crankshaft pulley.
2. Remove timing chain cover. (Scheme 11) Remove timing chain and crankshaft sprocket. See «PRIMARY TIMING CHAIN & SPROCKETS»(ref-9330-S04023445582000101800000) under REMOVAL & INSTALLATION. Remove oil pan. See «OIL PAN»(ref-9330-S09589599262000101800000) under REMOVAL & INSTALLATION. Remove oil pick-up tube and pick-up tube "O" ring. (Scheme 21) Remove oil pump bolts and oil pump.
3. Remove oil pump retainer cap. Remove spring and pressure relief valve. (Scheme 22) Remove oil pump cover and pump rotors. (Scheme 23) Clean all parts thoroughly.

Scheme 21

Scheme 22

Scheme 23

Reassembly & Installation

To reassemble, reverse disassembly procedure. Tighten cover bolts to specification. See TORQUE SPECIFICATIONS . Fill rotor cavity with engine oil before installation. To install, reverse removal procedure.

OIL PUMP SPECIFICATIONS