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Section 4 (2.0L Engine (Service Information)): Installation

WARNING: This page is about a different variant/trim than selected.
GC0182735Courtesy of CHRYSLER GROUP, LLC
  1. With the aid of a hydraulic lift, remove the engine from the maintenance stand and remove the maintenance stand mounting bracket (1) from the engine block.
    GC0180988Courtesy of CHRYSLER GROUP, LLC
  2. If removed, install the engine flexplate (1a) and tighten the NEW  bolts (1b) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
  3. Remove the (special tool #10272, Tool, Flywheel Locking) (2).
    GC0186749Courtesy of CHRYSLER GROUP, LLC
  4. If required, place the engine on the Dolly, Power Train (special tool #6135, Dolly, Power Train) (3) and the Cradle, Engine Support (special tool #6710A, Cradle, Engine Support) (2):
    • Loosen the cradle engine mounts to allow movement for positioning to the engine locating holes on the engine block and oil pan rail.
    • Lower the engine until it is resting on the posts.
    • Tighten the post mounts to the cradle frame.
    • Secure the engine to the dolly/cradle with safety straps (1).
    GC0186561Courtesy of CHRYSLER GROUP, LLC
  5. If removed, install the transmission (1) to the engine. Refer to INSTALLATION .
    GC0186678Courtesy of CHRYSLER GROUP, LLC
  6. Position the vehicle height to allow the power train dolly (3), cradle (2) and engine to be installed into the engine compartment. Slowly lower the vehicle to allow it to clear the powertrain assembly.
  7. Install the right engine mount insulator. Refer to INSTALLATION  .
    GC0186933Courtesy of CHRYSLER GROUP, LLC
  8. Install the three left engine mount insulator to bracket bolts (4) and tighten to the proper torque specification. Refer to (TORQUE SPECIFICATIONS ).
  9. Remove the strap and power train dolly from the engine.
    GC0186567Courtesy of CHRYSLER GROUP, LLC
  10. If removed, install the lower transmission mounting bolts (1) and tighten to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
    GC0177028Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    It is essential that correct length bolts be used to attach the converter to the driveplate. Failure to follow this caution may result in transmission damage.

  11. If removed, install six NEW  flexplate to torque converter bolts (1). Rotate the crankshaft counterclockwise (as viewed from the rear) to bring each of the bolts into view through the access opening and tighten to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
    GC0176954Courtesy of CHRYSLER GROUP, LLC
  12. Install the torque converter bolt access cover (1) to the oil pan.
    GC0159835Courtesy of CHRYSLER GROUP, LLC
  13. Place the ground cable in position on the transmission, install the ground cable bolt (1) and tighten to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
  14. Install the Power Transfer Unit (PTU), if equipped. Refer to INSTALLATION .
  15. Install the front suspension crossmember. Refer to CROSSMEMBER, REAR SUSPENSION, INSTALLATION .
  16. Install the rear engine mount insulator. Refer to INSTALLATION  .
  17. Install the front halfshafts. Refer to INSTALLATION .
  18. Install the exhaust cross-under pipe. Refer to INSTALLATION .
  19. Install the propeller shaft, if equipped. Refer to INSTALLATION .
  20. Install the front lower load beams. Refer to LOAD BEAM, LOWER, INSTALLATION .
    GC0159235Courtesy of CHRYSLER GROUP, LLC
  21. Engage the transmission solenoid wire harness connector into transmission connector.
  22. Rotate the lock lever (1) clockwise on the transmission solenoid wire harness connector.
    GC0160099Courtesy of CHRYSLER GROUP, LLC
  23. Place the shift cable and housing (2) in position on the mount bracket (1).
  24. Press the shift cable housing (2) into the mount bracket (1) on the transmission.
    GC0159736Courtesy of CHRYSLER GROUP, LLC
  25. Snap the shift cable end (2) in position on the manual lever on the transmission.
  26. Engage the transmission vent hose to the shift cable bracket.
  27. Engage the wire harness retainer to the shift cable bracket.
  28. Install the front fascia. Refer to FASCIA, FRONT, INSTALLATION .
  29. Install both front wheelhouse inner splash shields and the front tire and wheel assemblies. Refer to INSTALLATION .
    GC0159945Courtesy of CHRYSLER GROUP, LLC
  30. Guide the cooler lines (1) in position on the transmission.
  31. Engage the quick couplings to hold the cooler lines (1) to the transmission.
    GC0186611Courtesy of CHRYSLER GROUP, LLC
  32. Remove the tape or plugs from the opened refrigerant line fittings and the compressor ports.
  33. Lubricate NEW  O-ring seals with clean refrigerant oil and install them onto the refrigerant line fittings. Use only the specified O-ring seals as they are made of a special material for the system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  34. Install the A/C discharge and suction lines to the A/C compressor and tighten the two nuts to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
  35. Install the pressurized coolant bottle. Refer to INSTALLATION .
    GC0186399Courtesy of CHRYSLER GROUP, LLC
  36. Install the lower radiator hose (1) to the water pump inlet tube and tighten the band clamp.
    GC0186887Courtesy of CHRYSLER GROUP, LLC
  37. Install the upper radiator hose (1) to the thermostat housing (2) and tighten the band clamp.
    GC0186564Courtesy of CHRYSLER GROUP, LLC
  38. Install the charge air cooler hose (2) to the turbocharger coolant return pipe and tighten the band clamp.
  39. Install the coolant reservoir supply hose (1) to the turbocharger coolant return pipe and tighten the band clamp.
    GC0162199Courtesy of CHRYSLER GROUP, LLC
  40. Attach the wiring harness push pins (1) to the upper transmission housing.
    GC0162323Courtesy of CHRYSLER GROUP, LLC
  41. Place the ground cable and the wiring harness bracket in position on the transmission.
  42. Install the ground cable nut (2) and the wiring harness nut (1) to the top of the transmission and tighten to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
    GC0159257Courtesy of CHRYSLER GROUP, LLC
  43. Engage the wire harness connector (1) into the Transmission Control Module (TCM) connector.
  44. Close the lock on the TCM wire harness connector (1).
    GC0187026Courtesy of CHRYSLER GROUP, LLC
  45. Connect the heater core supply (2) and return (1) hoses at the quick-connect couplings.
  46. Install the catalytic converter. Refer to CONVERTER, CATALYTIC, INSTALLATION .
    GC0183549Courtesy of CHRYSLER GROUP, LLC
  47. Connect the fuel vapor supply pipe quick connect fitting to the purge solenoid (2).
    GC0186391Courtesy of CHRYSLER GROUP, LLC
  48. Connect the fuel supply hose quick connect fitting (2).
  49. Install the air cleaner body. Refer to INSTALLATION  .
  50. Install the clean air hose. Refer to INSTALLATION  .
  51. Engage the wire harness retainers to the battery tray.
  52. Install the Power Distribution Center (PDC). Refer to CENTER, POWER DISTRIBUTION (PDC), INSTALLATION .
  53. Install the Powertrain Control Module (PCM) mount and the PCM. Refer to MODULE, POWERTRAIN CONTROL (PCM), INSTALLATION .
  54. Install the battery. Refer to BATTERY, INSTALLATION .
  55. Install the top engine cover. Refer to COVER, ENGINE, INSTALLATION .
    GC0159542Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    A NEW  pinch bolt (3) must be installed every time the pinch bolt is removed.

  56. Install a NEW  intermediate shaft coupling bolt (3) and tighten to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
  57. Fill the cooling system. Refer to COOLING SYSTEM FILL 2.0L GMET4 .
  58. Connect the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector to the negative battery cable.
  59. Evacuate and charge the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE .
  60. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
  61. Remove the support and lower the vehicle.
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