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9 - 82
ENGINE 2.4L DOHC
ENGINE 2.4L DOHC (Continued)
STANDARD PROCEDURE - ENGINE CORE AND
OIL GALLERY PLUGS
Using a blunt tool such as a drift and a hammer,
strike the bottom edge of the cup plug. With the cup
plug rotated, grasp firmly with pliers or other suit-
able tool and remove plug (Fig. 5).
Fig. 5 Core Hole Plug Removal
1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
4 - DRIFT PUNCH
5 - CUP PLUG
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious
engine problems.
Thoroughly clean inside of cup plug hole in cylin-
der block or head. Be sure to remove old sealer.
Lightly coat inside of cup plug hole with Mopar
Stud and Bearing Mount. Make certain the new plug
is cleaned of all oil or grease. Using proper drive
plug, drive plug into hole so that the sharp edge of
the plug is at least 0.5 mm (0.020 in.) inside the
lead-in chamfer.
It is not necessary to wait for curing of the sealant.
The cooling system can be refilled and the vehicle
placed in service immediately.
REMOVAL - ENGINE ASSEMBLY
(1) Perform fuel pressure release procedure (Refer
to 14 - FUEL SYSTEM/FUEL DELIVERY - STAN-
DARD PROCEDURE).
(2) Disconnect negative battery cable.
(3) Drain cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(4) Discharge A/C system using a suitable refriger-
ant recovery machine.
(5) Remove throttle body air inlet hose and air
cleaner housing assembly.
(6) Remove upper radiator crossmember.
(7) Disconnect upper and lower radiator hoses at
radiator.
(8) Using a blade or suitable hose cutter, cut trans-
axle oil cooler lines off flush with fittings. Plug lines
and fittings to prevent debris from entering transaxle
or cooler circuit. A service splice kit will be installed
upon reassembly.
(9) Disconnect A/C lines at condenser. Remove
cooling module assembly (radiator, fan module, and
condenser).
(10) Disconnect transmission electrical harness
connectors (C104 & C105) (Refer to 8 - ELECTRI-
CAL/CONNECTOR/GROUND
DESCRIPTION).
(11) Disconnect transmission shift cable.
(12) Disconnect engine electrical harness from
PCM and bulkhead connectors.
(13) Raise vehicle on hoist.
(14) Remove both front wheels.
(15) Remove left and right splash shields.
(16) Remove both axle shafts (Refer to 3 - DIF-
FERENTIAL
&
DRIVELINE/HALF
REMOVAL).
(17) Drain engine oil.
(18) Remove accessory drive belts (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(19) Remove power steering pump from bracket.
Do not disconnect power steering lines from pump.
Reposition pump and support with suitable retaining
strap.
(20) Disconnect heater return hose from pipe con-
nection at right front frame rail area.
(21) Disconnect A/C compressor electrical connec-
tors.
(22) Disconnect exhaust pipe from manifold.
(23) Remove through bolts from front and rear
engine mounts.
(24) Remove rear mount bracket from transmis-
sion.
(25) Remove structural collar and torque reaction
bracket (Refer to 9 - ENGINE/ENGINE BLOCK/
STRUCTURAL COVER - REMOVAL).
(26) Mark flex plate to torque converter position.
Remove torque converter bolts.
(27) Lower vehicle.
(28) Disconnect positive cable from battery and
PDC.
(29) Disconnect ground cable from left side trans-
axle mount bracket.
(30) Disconnect throttle and speed control cables.
(31) Disconnect coolant recovery container over-
flow hose.
(32) Disconnect heater hose at thermostat housing.
JR
LOCATIONS
-
SHAFT
-
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