2.4 Liter (EDZ I4) engine removal suggestions save time compared to book instructions.

© DenLorsTools.com Summary: Removal instructions in the repair manual says to remove engine and transmission along with cradle from the bottom of the van. This engine can be removed from the top leaving the cradle, transmission and CV 1/2 shafts in place saving many hours of labor time! Included is a “stop motion” video showing removal and replacement – a time lapse showing in a couple of minutes the job that took 6 hours (book time is 13.9 hours). Applicable vehicles; 2001, 2002, 2003, 2004, 2005 2006 & 2007 Dodge Caravan and Town & Country mini vans w/2.4 4cyl.

Many times the car repair manual can save a lot of time by providing the exact information needed to complete a repair – no surprise right? On the other hand an experienced auto technician can read the repair information (or be aware of  how it outlines the procedure) and then decide if that’s the quickest way to approach the job or NOT. Flat rate tech’s are more likely to think like this. Cutting corners doesn’t have to mean shotty workmanship! Being able to change this motor from the top with an engine hoist, means that it can be changed without a vehicle lift.

Getting Ready to Pull the Motor

After disconnecting the battery, start by removing the wiper cowl assembly. Leave the transmission, half shafts and mounts attached to the trans. Removal of the hood makes for easier access and allows more light in the work area. Drain the engine oil and coolant – remove heater hoses that attach at the firewall.  Remove the splash shield near the right front wheel well. Remove accessory belts. A special harmonic balancer puller is required to take the crank shaft pulley off. Keep in mind that a harmonic balancer installer is going to be needed to properly re-install the pulley after the replacement motor is in. Removing the crankshaft pulley allows the room required to pull the engine out the top. Take the air filter assembly out and disconnect the fuel line near the throttle body. Remove wiring harness connectors that go to the engine and throttle cables with bracket. Remove the starter and access the torque converter bolts through that area. Remove the bracket that is near the rear of the oil pan. Unbolt the exhaust pipe and the exhaust manifold from the cylinder head – this will allow more room for removal by making the motor assembly less bulky. It’s best to remove the alternator and AC compressor before removal also. Keep in mind ac lines cannot be removed until the refrigerant is recovered with an AC machine. If they are removed with pressure in the lines personal injury may occur! Of course if the person attempting engine replacement doesn’t already know this, they’re going to run into many more problems than this car repair article could begin to cover! Support the transmission with a jack stand and a block of wood, the engine’s front mount should be freed enough to remove now. Find attaching points on the engine to hook the chain to. Hook up the engine hoist (Cherry Picker or Crane) and raise it up enough to begin lifting the weight. After removing the transmission bolts, raise the hoist a little more and the engine should be ready to separate from the transmission. By prying an wiggling the motor, it should come away. Care should be taken not to touch the sheet metal near the windshield. The stress of tweaking it even slightly may BREAK the windshield. While raising, look for remaining wires or anything that may still be attached. The motor will need to be angled to allow it to be raised out. Roll the engine hoist if needed, to help position the motor where it needs to go, being careful not to swing it towards the windshield. Naturally, install by reversing the steps above.

Final Suggestions/Tips

1. Use blue loctite on the flywheel bolts.

2. Use the correct puller and installer for the harmonic balancer (crank pulley).

3. Organize and label bolts (in bags if necessary). Even if you can figure out where they go, it saves time not to have to think about it.

4. Consider changing the timing belt, water pump, cam and crank seals including the rear main seal if installing a used motor. It’s obviously the time to do these preventive maintenance items while the engine is out. Salvage yards recommend replacing these items prior to installation and will not warranty the used  parts that come with the engine.

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