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Installation - Engine

CAUTION:

If the original engine has experienced a catastrophic failure or an individual failure with the piston, cylinder bore, engine block, valve or valve seat, the intake manifold MUST be replaced with a new manifold.

Fig 1: Identifying Lift Chain
GC0084922Courtesy of CHRYSLER GROUP, LLC
  1. Position engine over engine compartment and slowly lower into place.
  2. Align engine and transaxle.
  3. Install upper bellhousing bolts and tighten.
    Fig 2: Right Engine Mount
    GC0098690Courtesy of CHRYSLER GROUP, LLC
  4. Install mounting bolts (3) at the right mount bolts and tighten bolts to 118 N.m (87 ft. lbs.).
    Fig 3: Modular Clutch To Flex Plate Bolts
    GC0084923Courtesy of CHRYSLER GROUP, LLC
  5. Install clutch to flex plate bolts (1).
  6. Install lower bell housing bolts (2) and tighten.
    Fig 4: Inspection Cover
    GC0098691Courtesy of CHRYSLER GROUP, LLC
  7. Install inspection cover (1).
    Fig 5: Crankshaft Position Sensor
    GC0098692Courtesy of CHRYSLER GROUP, LLC
  8. Connect crankshaft position sensor (2). Connect crankshaft position sensor electrical connector.
  9. On AWD vehicles, install maniverter. Refer to MANIFOLD, EXHAUST, INSTALLATION .
    Fig 6: Ground Strap
    GC0098693Courtesy of CHRYSLER GROUP, LLC
  10. Install Ground strap (1).
  11. Raise vehicle.
    Fig 7: Exhaust To Maniverter Bolts
    GC0084924Courtesy of CHRYSLER GROUP, LLC
  12. On AWD vehicles, install maniverter to exhaust pipe bolts (1) and tighten bolts.
    Fig 8: Exhaust Pipe & Suitable Strap
    GC0084925Courtesy of CHRYSLER GROUP, LLC
  13. On FWD vehicles, remove strap (2) from exhaust pipe (1).
    Fig 9: Exhaust Pipe To Manifold, Heat Shield & Oxygen Sensor Electrical Connector
    GC0084926Courtesy of CHRYSLER GROUP, LLC
  14. On FWD vehicles, install new manifold to catalytic converter gasket (1) and install catalytic converter to exhaust manifold and tighten.
  15. Connect oxygen sensor electrical connector (3).
  16. Install generator.
    Fig 10: A/C Compressor
    GC0084927Courtesy of CHRYSLER GROUP, LLC
  17. Install A/C compressor (1).
    Fig 11: Damper Removal
    GC0084928Courtesy of CHRYSLER GROUP, LLC
  18. Install crankshaft damper.
  19. Apply clean engine oil crankshaft damper bolt threads and between bolt head and washer. Tighten bolt to 210 N.m (155 ft. lbs.).
  20. Install right splash shield.
  21. Install right tire.
    Fig 12: Oil Cooler
    GC0084929Courtesy of CHRYSLER GROUP, LLC
  22. Install oil cooler if equipped (2). Refer to COOLER, OIL, INSTALLATION .
  23. Connect coolant hoses to oil cooler (2), if equipped.
  24. Install new oil filter (3).
  25. Lower vehicle.
  26. Install upper idler pulley.
    Fig 13: Power Steering Line Support
    GC0098694Courtesy of CHRYSLER GROUP, LLC
  27. Install power steering pump.
  28. Install power steering line support bracket at engine mount (1).
    Fig 14: P/S Hose Support - FWD
    GC0084930Courtesy of CHRYSLER GROUP, LLC
  29. On FWD vehicles, install power steering hose support (2) at exhaust manifold.
  30. Install accessory drive belt.
    Fig 15: Intake Manifold Bolt Removal & Tightening Sequence
    GC0098575Courtesy of CHRYSLER GROUP, LLC
  31. Connect electrical connectors at block ground, starter, A/C compressor, knock sensor, Oil pressure sensor, generator, Coolant temperature sensor at block, and block heater.
  32. Install intake manifold and tighten bolts as shown in illustration.
    Fig 16: Throttle Body Support
    GC0098695Courtesy of CHRYSLER GROUP, LLC
  33. Install throttle body support bracket (1).
  34. Install engine oil dip stick.
  35. Install vacuum lines at throttle body and intake manifold.
  36. Connect manifold flow control valve and electronic throttle control electrical connectors and fasten harness to intake.
    Fig 17: Ignition Coils, Air Hose, Fuel Line, Injectors & PCV Hose
    GC0084931Courtesy of CHRYSLER GROUP, LLC
  37. Install intake air tube on throttle body.
  38. Install PCV hose (5) to valve cover.
  39. Connect the fuel line (3) to the fuel rail.
  40. Connect coils (1), injectors (4), oil temperature sensor and cam position sensors.
    Fig 18: Radiator Hose Support
    GC0098696Courtesy of CHRYSLER GROUP, LLC
  41. Install upper radiator support bracket (1).
    Fig 19: Coolant Temperature Sensor, Capacitor Electrical Connector & Coolant Adapter
    GC0084932Courtesy of CHRYSLER GROUP, LLC
  42. Connect engine coolant temperature sensor (1), and capacitor (2).
  43. Install coolant hoses at coolant adapter (3).
  44. Connect purge hose (4).
    Fig 20: Windshield Washer Reservoir, Power Steering Reservoir & Coolant Reservoir
    GC0098697Courtesy of CHRYSLER GROUP, LLC
  45. Install coolant reservoir (3) and connect hose.
    Fig 21: Battery Tray
    GC0098698Courtesy of CHRYSLER GROUP, LLC
  46. Install the battery tray (1). Refer to TRAY, BATTERY, INSTALLATION .
    Fig 22: Air Cleaner Body, Air Inlet Tube & Make-Up Air Hose
    GC0145278Courtesy of CHRYSLER GROUP, LLC
  47. Push down on the air cleaner body (1) to engage the pins into the grommets.
  48. Install the support bracket bolt to the strut tower and tighten to 10 N.m (89 in. lbs.).
  49. Install the air inlet tube (2) to the air cleaner body (1).
  50. Connect the make-up air hose (3) to the air cleaner body.
    Fig 23: Electrical Connectors, PCM, Three Mounting Bolts & Ground Wire
    GC0145274Courtesy of CHRYSLER GROUP, LLC
  51. Install the mounting bolt (3) with ground wire (1) and tighten to 12 N.m (106 in. lbs.).
  52. Connect and lock the electrical connectors (2).
    Fig 24: Retainers, Fresh Air Inlet Duct & Air Cleaner Body
    GC0145275Courtesy of CHRYSLER GROUP, LLC
  53. Install the battery and connect the battery cables. Refer to BATTERY, INSTALLATION .
  54. Install the fresh air inlet duct (3) on the air cleaner body (1) and lock the retainers (2).
    Fig 25: Engine Cover - 2.4L
    GC0084936Courtesy of CHRYSLER GROUP, LLC
  55. Install the hood. Refer to HOOD, INSTALLATION .
  56. Fill with coolant. Refer to STANDARD PROCEDURE .
  57. Fill with oil.
  58. Start engine and check for leaks.
  59. Install engine cover (1).
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