How to Remove a Dodge Van Motor

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    • 1). Evacuate the Freon. If you do not have a reclaimer, take the van to a shop to have them evacuate it for you. It is illegal to evacuate Freon into the atmosphere. If you have air conditioning, but there is no Freon in the system, or if you do not have air, skip this step.

    • 2). Relieve the fuel system pressure by pulling the fuel pump relay, located in the relay box on the driver's side of the engine compartment, and turning the engine over two or three times. Disconnect the negative battery cable and lay it aside, ensuring that it does not touch metal. Disconnect the positive battery cable.

    • 3). Place one drain pan under the oil pan. Drain the oil by removing the oil drain pan plug. Place the other drain pan under the petcock for the radiator. Loosen the petcock to drain the radiator.

    • 4). Remove the engine cover (inside the van). Remove the air cleaner assembly by loosening the wingnut on top of the air cleaner in older systems, or loosening the hose clamps on the duct work, removing the ducts, and unbolting the air cleaner box on the newer systems.

    • 5). Work the oil dipstick tube back and forth as you are pulling on it to remove it from the engine. Unbolt and remove the front bumper. Remove the grill and support brace using the appropriate socket or wrench. Unbolt and remove the cowl plenum-to-upper radiator supports using the appropriate socket.

    • 6). Remove the coolant recovery bottle using the appropriate socket if it is bolted in. Sometimes, it just sits in a holder. Unbolt and remove the windshield washer bottle. Unbolt and remove the fan shroud and fan using the appropriate sockets. Loosen the tensioners on the drive belts to release tension on the belts and remove the belts. If the tensioner is a slider type, loosen the bolt in the slider and push the accessory toward the engine. If the drive belt uses a tensioner pulley, push the pulley toward the engine using the appropriate socket or wrench.

    • 7). Loosen the clamps on the upper and lower radiator hoses using a screwdriver, pliers or the appropriate socket, depending on the type of clamp used. Pull the radiator hoses off the radiator and the engine. Unscrew and remove the transmission cooler lines from the radiator or transmission cooler. Loosen the clamps on all heater hoses, then remove the hoses.

    • 8). Disconnect the air conditioning lines at the condenser using the appropriate wrench. Cover the openings of the air conditioning lines with tape. Remove the radiator and condenser using the appropriate sockets. Unbolt and remove the air compressor, if applicable. Unbolt the power steering pump, but leave the lines attached. Move the pump out of the way.

    • 9). Label the wires on the back of the alternator with the tape. Remove the wires using the appropriate wrench. Unbolt and remove the alternator. Label all hoses and vacuum lines that are still hooked up to the engine with the tape. Remove the hoses from the engine by loosening their clamps. Remove the vacuum pump if your year and model uses a vacuum pump, using the appropriate socket. Disconnect the wiring harness plugs from the sensors. Remove the spark plug wires by pulling them off the spark plugs.

    • 10

      Disconnect the fuel lines using the appropriate wrench. Unbolt and remove the throttle body assembly. Raise the van with the floor jack and support it with jack stands. Unscrew the oil filter using the oil filter wrench. Unbolt and remove the oil pan. Pull the oil pump pick-up tube assembly off the oil pump, then remove the oil pump using the appropriate sockets.

    • 11

      Remove the starter using the appropriate socket. Unplug the oxygen sensor plug. Unbolt and remove the exhaust crossover pipe. Remove the torque converter cover using the appropriate sockets. Turn the flexplate with the flywheel turner until you see one of the torque converter bolts. Remove the bolt. Repeat until all the torque converter bolts have been removed.

    • 12

      Slide the floor jack under the transmission and jack it up so that it just touches the bottom of the transmission. Remove the bell housing bolts. Use the prybar to separate the transmission and the engine, if needed.

    • 13

      Attach the engine hoist to the engine. Jack it up enough so that the engine's weight is off the motor mounts. Remove the nuts and washers from the motor mounts. Unbolt and remove the left exhaust manifold. Raise the engine out of the van using the engine hoist and place the engine on an engine stand.

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