92 voyagerMay 3, 2015May 3, 2015. I want to know the best way to remove a 3.0 engine from a 1999 Plymouth voyager minivan: top , bottom, or separately? Keywords:engine removevoyager 1 thought on “92 voyager” Freeautomechanic May 5, 2015 at 9:14 am This is How Chilton Suggests you do it. Engine removal and installation procedures are similar on all models. 1.Disconnect the negative battery cable. 2.Scribe the hood hinge outlines on the hood, and remove the hood. 3.Drain the cooling system. Remove the radiator hoses from the radiator and engine connections. CAUTION When draining coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old. 4.Remove the radiator and fan assembly. 5.Remove the air conditioner compressor from the engine with the mounting brackets and hoses connected. Position the assembly to the side and secure out of the way. 6.Remove the power steering pump from the engine with mounting brackets and hoses connected. Position the assembly to the side and secure out of the way. 7.Remove all electrical connectors at the alternator, carburetor, injection unit and engine. 8.Unfasten the fuel line(s) from the engine. Disconnect the heater hoses from the engine. Remove the accelerator cable from the carburetor or throttle body. 9.Remove the alternator. Disconnect the clutch cable from the clutch lever, if equipped with a manual transaxle. 10.Remove the transaxle case lower cover. 11.On automatic transaxles, mark the flexplate-to-torque converter location. Remove the bolts that mount the converter to the flexplate. Attach a small C-clamp to the front bottom of the converter housing to prevent the converter from falling off of the transaxle. 12.Disconnect the starter motor wiring and remove the starter motor. 13.Disconnect the exhaust pipe from the exhaust manifold. 14.If not done already for access, remove the right inner engine splash shield. Drain the engine oil and remove the oil filter. Disconnect the engine ground strap. CAUTION The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. 15.Attach a hoist to the engine. 16.Support the transaxle with a hydraulic floor jack. Apply slight upward pressure with the chain hoist and remove the through-bolt from the right (timing case cover) engine mount. NOTE: If the complete engine mount is to be removed, mark the insulator position on the side rail to insure exact reinstallation location. 17.Remove the transaxle-to-cylinder block mounting bolts. 18.Remove the front engine mount through-bolt. Remove the manual transaxle anti-roll strut. 19.Remove the insulator through-bolt from the inside wheel house mount, or remove the insulator bracket-to-transaxle mounting bolt. 20.Raise the engine slowly with the hoist (transaxle supported). Separate the engine from the transaxle, then remove the engine. To install: 21.With the hoist attached to the engine. Lower the engine into engine compartment. 22.Align the converter to the flexplate and the engine mounts. Install all mounting bolts loosely until all are in position, then tighten to 40 ft. lbs. (55 Nm). 23.Install the engine-to-transaxle mounting bolts. Tighten to 70 ft. lbs. (95 Nm) for the 2.2L, 2.5L and 3.0L engines and to 75 ft. lbs. (100 Nm) for the 3.3L and 3.8L engines. 24.Remove the engine hoist from the engine and transaxle support. 25.Secure the engine ground strap. 26.Install the inner splash shield. 27.Install the starter assembly. 28.Install the exhaust system to the exhaust manifolds. 29.On manual transaxle equipped vehicles, install the transaxle case lower cover. Connect the clutch cable. 30.For automatic transaxles, remove the C-clamp from the torque converter housing. Align flexplate and torque converter with the mark previously made, if applicable. Install the converter-to-flexplate mounting screws, then tighten to 40 ft. lbs. (55 Nm). Install the case lower cover. 31.Install the power steering pump. 32.Install the air conditioning compressor. 33.Install the alternator. 34.Connect all wiring to the engine accessories. 35.Install the radiator, fan and shroud assembly. 36.Connect all cooling system hoses, accelerator cable and fuel lines. 37.Install the engine oil filter. Fill the crankcase to proper oil level. 38.Fill the cooling system. 39.Adjust the accelerator and transaxle linkages. 40.Install the air cleaner and hoses. 41.Install the hood so that the scribe marks on the hood align with the hinges. 42.Connect the battery cables, positive cable first. 43.Start the engine and run until normal operation temperature is indicated. Adjust the carburetor and check for any fuel, coolant, oil and transaxle fluid leaks. Comments are closed.