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Home >> Dodge and Ram >> 2021 >> ProMaster City Base >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> 2.4L Engine (Service Information) >> Removal And Installation >> Installation

Removal And Installation: Installation

GC0171474Courtesy of CHRYSLER GROUP, LLC
  1. 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).
    GC0170013Courtesy of CHRYSLER GROUP, LLC
  2. If required, install the flexplate (1) to the crankshaft with the washer (2) and seven new  flexplate bolts (3) tighten in a criss-cross pattern to the proper torque specification. Refer to TORQUE SPECIFICATIONS TECHNICAL SPECIFICATIONS .
    NOTE:

    Perform the following steps to install the transmission to the engine if required.

  3. Lightly grease the torque converter hub pocket in the end of the crankshaft.
    NOTE:

    The close tolerance torque converter bolt hole is oval shaped, and will aid in aligning the flexplate to the torque converter if the torque converter bolt is installed in this location first.

  4. Rotate the flexplate so the close tolerance bolt hole is at the six o'clock position.
  5. Push the bell housing against the engine block and engage the guide pins.
    GC0171889Courtesy of CHRYSLER GROUP, LLC
  6. Align the wire harness bracket (2) and install the engine block to transmission bolt (1) hand tight.
    GC0171715Courtesy of CHRYSLER GROUP, LLC
  7. Install the starter (2) and the lower starter bolt (1) hand tight.
    GC0171816Courtesy of CHRYSLER GROUP, LLC
  8. Install the three bolts (1) to hold the oil pan to the transmission hand tight.
    GC0171973Courtesy of CHRYSLER GROUP, LLC
  9. Install the transmission to engine bolt (1) hand tight.
    GC0171937Courtesy of CHRYSLER GROUP, LLC
  10. Install the left upper transmission to engine bolt (2) through the wiring harness bracket (1) hand tight.
    GC0171700Courtesy of CHRYSLER GROUP, LLC
  11. Install the right upper transmission to engine bolt (1) hand tight.
  12. Install the upper starter bolt (2) and tighten all nine installed bolts to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0160135Courtesy 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.

  13. Through the access door opening, install NEW  bolts (1) to hold the flexplate to the torque converter hand tight. Rotate the crankshaft to bring each set of bolts into view through the access door.
    NOTE:

    There are three pairs of bolts 120° apart attaching the flexplate to the torque converter.

  14. Tighten all the torque converter bolts to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0171533Courtesy of CHRYSLER GROUP, LLC
  15. Install the torque converter bolt access door (1) and tighten the bolt (2) to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0171462Courtesy of CHRYSLER GROUP, LLC
  16. Install a new exhaust manifold gasket (1) DO NOT APPLY SEALER  .
    GC0155999Courtesy of CHRYSLER GROUP, LLC
  17. Set the manifold into position and install the manifold bolts.
  18. Tighten the bolts following the sequence shown in illustration to the proper torque specification. Refer to TORQUE SPECIFICATIONS TECHNICAL SPECIFICATIONS .
    GC0156381Courtesy of CHRYSLER GROUP, LLC
  19. Install the catalytic converter heat shields to the exhaust manifold and tighten the bolts to the proper torque specification. Refer to TORQUE SPECIFICATIONS TECHNICAL SPECIFICATIONS .
  20. Install the upstream and downstream oxygen sensors. Refer to SENSOR, OXYGEN, REMOVAL AND INSTALLATION .
    GC0171378Courtesy of CHRYSLER GROUP, LLC
  21. Install the catalytic converter lower support bracket (1) and tighten the bolts (2, 3) to the proper torque specification. Refer to TORQUE SPECIFICATIONS TECHNICAL SPECIFICATIONS .
    GC0171474Courtesy of CHRYSLER GROUP, LLC
  22. 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.
  23. Install the right engine mount insulator. Refer to INSULATOR, ENGINE MOUNT, RIGHT, REMOVAL AND INSTALLATION .
  24. Install the left engine mount insulator. Refer to INSULATOR, ENGINE MOUNT, LEFT, REMOVAL AND INSTALLATION  .
  25. Remove the strap (1) and the power train dolly (3).
  26. Raise and support the vehicle.
  27. Install the front suspension crossmember. Refer to CROSSMEMBER, FRONT SUSPENSION, REMOVAL AND INSTALLATION .
  28. Install the rear engine mount insulator. Refer to INSULATOR, ENGINE MOUNT, REAR, REMOVAL AND INSTALLATION  .
    GC0171187Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Left side shown in illustration, right side similar.

  29. Position the lower radiator core support (4), while aligning the radiator to the bushings (1) and install the two lower bolts (3) hand tight.
    GC0171251Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Left side shown in illustration, right side similar.

  30. Place the left and right lower load beams (2) in position and hand start the two lower load beam to cradle bolts (1).
    GC0171854Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Left side shown in illustration, right side similar.

  31. Install the four bolts (1) to hold the front of the right and left load beams to the radiator support panel and tighten all the installed bolts to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0171550Courtesy of CHRYSLER GROUP, LLC
  32. Place the ground cable (1) in position on the transmission and tighten the bolt (2) to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
  33. Install the left and right half shafts. Refer to REMOVAL AND INSTALLATION .
  34. Install the exhaust pipe. Refer to PIPE, EXHAUST, REMOVAL AND INSTALLATION .
    GC0171232Courtesy of CHRYSLER GROUP, LLC
  35. Install the front crossmember bracket (1) and tighten the bolts (2) to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0171399Courtesy of CHRYSLER GROUP, LLC
  36. Remove the tape or plugs from the opened refrigerant line fittings and the A/C compressor ports.
  37. 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.
  38. Install the A/C discharge line/suction line manifold (1) to the A/C compressor (2) and tighten the nut (3) to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
  39. Connect the transmission cooler lines to the transmission. Refer to TUBES AND HOSES, TRANSMISSION OIL COOLER, STANDARD PROCEDURE .
    GC0171975Courtesy of CHRYSLER GROUP, LLC
  40. Install the right lower splash shield (1) with four bolts (3 and 4) and screw (2) tightened to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0171903Courtesy of CHRYSLER GROUP, LLC
  41. Remove the support and lower the vehicle.
  42. Install the wire harness routing bracket (2) with two bolts (1) and tighten to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
  43. Connect and lock the engine wire harness connector (3).
    GC0171230Courtesy of CHRYSLER GROUP, LLC
  44. Connect the transmission wire harness connector (1) to the transmission and rotate the locking lever (2) clockwise.
    GC0171327Courtesy of CHRYSLER GROUP, LLC
  45. If required, install the shifter cable bracket (3) and tighten the bolts (2) to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0169088Courtesy of CHRYSLER GROUP, LLC
  46. Hold down the release button (2) down while attaching the shifter cable end (1) to the manual lever (3).
    GC0172072Courtesy of CHRYSLER GROUP, LLC
  47. Install the heater core outlet hose (2) to the coolant return pipe with the CLIC E®  type clamp using the Pliers, Hose Clamp (special tool #10288, Pliers, Hose Clamp).
  48. Install the heater core inlet hose (1) to the thermostat housing and engage the quick-connect coupling.
    GC0171442Courtesy of CHRYSLER GROUP, LLC
  49. Secure the heater core hoses in the retainer (1) at the rear of the transmission.
    GC0172043Courtesy of CHRYSLER GROUP, LLC
  50. Install the engine oil cooler inlet (1) and outlet (2) hoses with the CLIC E®  type clamp using the Pliers, Hose Clamp (special tool #10288, Pliers, Hose Clamp).
    GC0171629Courtesy of CHRYSLER GROUP, LLC
  51. Install the upper radiator inlet (2) and lower radiator outlet (1) hoses with the CLIC E®  type clamp using the Pliers, Hose Clamp (special tool #10288, Pliers, Hose Clamp).
  52. Connect the block heater wire harness connector (3) if equipped.
    GC0171271Courtesy of CHRYSLER GROUP, LLC
  53. Engage the wire harness retainer (1) to the upper radiator inlet hose at the thermostat housing.
    GC0171675Courtesy of CHRYSLER GROUP, LLC
  54. Install the upper radiator inlet hose (1) to the radiator and engage the quick-connect coupling.
    GC0172014Courtesy of CHRYSLER GROUP, LLC
  55. Install the lower radiator outlet hose (1) to the radiator and engage the quick-connect coupling.
    GC0171597Courtesy of CHRYSLER GROUP, LLC
  56. Install the degas hose (4) to the pressurized coolant bottle (1) with the CLIC E®  type clamp using the Pliers, Hose Clamp (special tool #10288, Pliers, Hose Clamp).
    GC0172053Courtesy of CHRYSLER GROUP, LLC
  57. Connect the vacuum hose quick-connect fitting (1) to the vacuum pump and secure the vacuum hose to the support bracket (2).
    GC0171241Courtesy of CHRYSLER GROUP, LLC
  58. Connect the starter cable (1) to the power distribution center and tighten the nut to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
  59. Connect the generator cable (2) to the power distribution center and tighten the nut to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0169971Courtesy of CHRYSLER GROUP, LLC
  60. Install the injector silencer pad (3) over the fuel rail.
  61. Connect fuel line (1) to the fuel rail. Refer to FITTING, QUICK CONNECT, STANDARD PROCEDURE .
  62. Connect the purge vapor line (2) to the purge solenoid. Refer to FITTING, QUICK CONNECT, STANDARD PROCEDURE .
    GC0190611Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The support bracket must be installed on the power steering pump before pump installation.

  63. Install the power steering pump (1) in the mounting bracket with three bolts (2) hand tight.
  64. Install the nut (3) to the support bracket and tighten the nut and three bolts (2) to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0190604Courtesy of CHRYSLER GROUP, LLC
  65. Install the power steering hose support brackets to the cylinder head cover and tightened the nuts (1) to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0171976Courtesy of CHRYSLER GROUP, LLC
  66. Install the power steering pump pulley (1) with three bolts (2) tightened to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
  67. Install the accessory drive belt and belt cover. Refer to BELT, SERPENTINE, REMOVAL AND INSTALLATION .
  68. Install the right front wheelhouse splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, REMOVAL AND INSTALLATION .
  69. Install the front tire and wheel assemblies. Refer to REMOVAL AND INSTALLATION .
  70. Install the battery tray and battery. Refer to TRAY, BATTERY, REMOVAL AND INSTALLATION .
  71. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to OIL, STANDARD PROCEDURE .
  72. Fill the transmission. Refer to STANDARD PROCEDURES .
  73. Fill the cooling system. Refer to STANDARD PROCEDURE .
  74. Install the front fascia. Refer to FASCIA, FRONT, REMOVAL AND INSTALLATION .
  75. Install the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL AND INSTALLATION .
  76. Install the clean air hose and engine cover. Refer to HOSE, CLEAN AIR, REMOVAL AND INSTALLATION .
  77. Connect the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector.
  78. Evacuate and charge the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE .
  79. Start engine and check for leaks.
  80. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to STANDARD PROCEDURE .
NOTE:

The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components. Refer to STANDARD PROCEDURE .

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