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Installation - Engine

WARNING: This page is about a different variant/trim than selected.
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: Right Engine Mount
GC0098582Courtesy of CHRYSLER GROUP, LLC
  1. Position engine assembly over vehicle and slowly lower the engine into place.
  2. Continue lowering engine until engine and transaxle are aligned. to mounting locations.
  3. Install engine mount adapter (2) and tighten bolts (3). Install mount through bolt (4) and tighten to 118 N.m (87 ft. lbs.).
    Fig 2: Identifying Lift Chain
    GC0084090Courtesy of CHRYSLER GROUP, LLC
  4. Remove engine lift chain (1).
  5. Install oil control valve.
    Fig 3: A/C Compressor
    GC0084091Courtesy of CHRYSLER GROUP, LLC
  6. Raise vehicle.
  7. Install A/C compressor (1).
    Fig 4: Removing/Installing Exhaust Manifold, Heat Shields, & Oxygen Sensor
    GC0084092Courtesy of CHRYSLER GROUP, LLC
  8. Install exhaust manifold and heat shields (2). Refer to MANIFOLD, EXHAUST, INSTALLATION .
  9. Install oxygen sensor and connect electrical connector (3).
    Fig 5: Crankshaft Position Sensor
    GC0098583Courtesy of CHRYSLER GROUP, LLC
  10. Install crankshaft position sensor (2) and connect connector.
    Fig 6: Removing/Installing Exhaust Manifold, Heat Shields, & Oxygen Sensor
    GC0084092Courtesy of CHRYSLER GROUP, LLC
  11. Install manifold to exhaust pipe bolts (1) and tighten bolts.
  12. Install generator.
    Fig 7: Modular Clutch To Flex Plate Bolts
    GC0084093Courtesy of CHRYSLER GROUP, LLC
  13. Install lower bell housing bolts (2) and tighten bolts.
  14. Align torque converter and flex plate mark. Install torque converter bolts (1) and tighten.
    Fig 8: Inspection Cover
    GC0098584Courtesy of CHRYSLER GROUP, LLC
  15. Install inspection cover (1).
    Fig 9: Removing/Installing Damper Bolt
    GC0084094Courtesy of CHRYSLER GROUP, LLC
  16. Install crankshaft damper
  17. Install Damper holder (special tool #9707, Holder, Vibration Damper) (1).
  18. Apply clean engine oil crankshaft damper bolt threads and between bolt head and washer. Tighten bolt to 210 N.m (155 ft. lbs.).
  19. Install right splash shield.
  20. Install tire.
    Fig 10: Oil Cooler
    GC0084095Courtesy of CHRYSLER GROUP, LLC
  21. Install coolant hose to oil cooler (2).
  22. Install new oil filter (3).
  23. Lower vehicle.
  24. Install upper idler pulley.
    Fig 11: Coolant Adapter
    GC0084096Courtesy of CHRYSLER GROUP, LLC
  25. Install coolant adapter assembly (3).
    Fig 12: Ground Strap
    GC0098585Courtesy of CHRYSLER GROUP, LLC
  26. Install Ground strap (1) near right strut tower.
    Fig 13: Power Steering Line Support
    GC0098586Courtesy of CHRYSLER GROUP, LLC
  27. Install power steering line support bracket (1).
  28. Install power steering pump.
  29. Install accessory drive belt.
  30. Connect electrical connectors at block ground, starter, A/C compressor, knock sensor, Oil pressure sensor, generator, Coolant temperature sensor at block, and block heater (if equipped).
    Fig 14: Intake Manifold Bolt Removal & Tightening Sequence
    GC0098575Courtesy of CHRYSLER GROUP, LLC
  31. Install intake manifold and tighten bolts as shown in illustration.
    Fig 15: Throttle Body Support
    GC0098587Courtesy of CHRYSLER GROUP, LLC
  32. Install throttle body support bracket (1).
  33. Install harness retainer (2).
  34. Install engine oil level indicator.
    Fig 16: Ignition Coils, Air Hose, Fuel Line, Injectors & PCV Hose
    GC0084097Courtesy of CHRYSLER GROUP, LLC
  35. Install PCV hose (5) to valve cover.
  36. Install make-up air hose (2).
  37. Connect manifold flow control valve and electronic throttle control electrical connectors.
  38. Install vacuum lines at throttle body and intake manifold.
  39. Install intake air tube to throttle body.
    Fig 17: Ignition Coils, Air Hose, Fuel Line, Injectors & PCV Hose
    GC0084097Courtesy of CHRYSLER GROUP, LLC
  40. Connect coil electrical connectors (1).
  41. Connect injector electrical connectors (4).
  42. Connect fuel line (3) to rail.
  43. Connect intake and exhaust oil control valve electrical connectors.
    Fig 18: Radiator Hose Support
    GC0098588Courtesy of CHRYSLER GROUP, LLC
  44. Install grill trim panel.
  45. Install upper radiator support bracket (1).
    Fig 19: Coolant Adapter
    GC0084096Courtesy of CHRYSLER GROUP, LLC
  46. Connect coolant temperature sensor (1).
  47. Connect capacitor electrical connector (2).
  48. Install coolant hoses at coolant adapter (3).
    Fig 20: Coolant Reservoir
    GC0098589Courtesy of CHRYSLER GROUP, LLC
  49. Install coolant reservoir (3) and connect hose.
    Fig 21: Battery Tray
    GC0098590Courtesy of CHRYSLER GROUP, LLC
  50. 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
  51. Push down on the air cleaner body (1) to engage the pins into the grommets.
  52. Install the support bracket bolt to the strut tower and tighten to 10 N.m (89 in. lbs.).
  53. Install the air inlet tube (2) to the air cleaner body (1).
  54. 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
  55. Install the mounting bolt (3) with ground wire (1) and tighten to 12 N.m (106 in. lbs.).
  56. Connect and lock the electrical connectors (2).
    Fig 24: Retainers, Fresh Air Inlet Duct & Air Cleaner Body
    GC0145275Courtesy of CHRYSLER GROUP, LLC
  57. Install the battery and connect the battery cables. Refer to BATTERY, INSTALLATION .
  58. Install the fresh air inlet duct (3) on the air cleaner body (1) and lock the retainers (2).
    Fig 25: Engine Cover - 2.0L
    GC0098591Courtesy of CHRYSLER GROUP, LLC
  59. Install the hood. Refer to HOOD, INSTALLATION .
  60. Fill with coolant. Refer to STANDARD PROCEDURE .
  61. Fill with oil.
  62. Start engine and check for leaks.
  63. Install engine cover (1).
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