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Frame, Ladder: Installation

GC0121276Courtesy of CHRYSLER GROUP, LLC
  1. Clean the ladder frame sealing surfaces with isopropyl alcohol in preparation for sealant application.
    CAUTION:

    Engine assembly requires the use of a unique sealant that is compatible with engine oil. Using a sealant other than Mopar® Engine Sealant RTV Silicone Rubber Adhesive may result in engine fluid leakage.

    CAUTION:

    Following the application of Mopar® Engine Sealant RTV Silicone Rubber Adhesive to the gasket surfaces, the components must be assembled within 10 minutes and the attaching fasteners must be tightened to specification within the next 10 minutes. Prolonged exposure to the air prior to assembly may result in engine fluid leakage.

  2. Apply a 2 mm bead of Mopar® Engine Sealant RTV Silicone Rubber Adhesive as shown in illustration.
    Fig 1: Ladder Frame Bolts Tightening Sequence
    GC0121277Courtesy of CHRYSLER GROUP, LLC
  3. Install the ladder frame and tighten the twelve bolts in the sequence shown in illustration, following this 2 step method. Tighten according to the following torque values:
    • Step 1: All to 10 N. m (89 in. lbs.).
    • Step 2: All to 26 N. m (19 ft. lbs.).
  4. Install the balance shaft/oil pump assembly. Refer to INSTALLATION  .
  5. Install the engine timing cover, oil pan and cylinder head cover. Refer to INSTALLATION  .
    GC0169431Courtesy of CHRYSLER GROUP, LLC
  6. Install the intermediate shaft bearing housing (1) with three bolts (2) tightened to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0156353Courtesy of CHRYSLER GROUP, LLC
  7. Install the lower intake manifold support bracket (3) with two nuts (1) and one bolt (2) tightened to the proper torque specification. Refer to (TORQUE SPECIFICATIONS ).
    GC0169358Courtesy of CHRYSLER GROUP, LLC
  8. Install the generator mounting bracket (1) with three bolts (2) tightened to the proper torque specification. Refer to (TORQUE SPECIFICATIONS ).
  9. If removed, install the accessory belt tensioner (3) to the generator mounting bracket with two bolts tightened to the proper torque specification. Refer to (TORQUE SPECIFICATIONS .
    GC0169955Courtesy of CHRYSLER GROUP, LLC
  10. Install a new O-ring seal (1) on the engine oil dipstick tube lubricated with clean engine oil.
    GC0169172Courtesy of CHRYSLER GROUP, LLC
  11. Install the oil dipstick tube (1) to the engine with the bolt (2) tightened to the proper torque specification. Refer to (TORQUE SPECIFICATIONS ).
    GC0156074Courtesy of CHRYSLER GROUP, LLC
  12. Install the generator to the generator mounting bracket. Tighten the upper bolt (1) and lower bolts (4) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
  13. Install the positive cable to the generator stud (2) and tighten the nut to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
  14. Connect the generator field harness connector (3).
    GC0165547Courtesy of CHRYSLER GROUP, LLC
  15. Install a new engine oil cooler seal lubricated with clean engine oil.
  16. Position the notch in the engine oil cooler to the tab (a) on the oil filter adapter.
    GC0165352Courtesy of CHRYSLER GROUP, LLC
  17. Install the oil cooler connector bolt (1) and tighten to the proper torque specification. Refer to (TORQUE SPECIFICATIONS ).
    GC0169964Courtesy of CHRYSLER GROUP, LLC
  18. If removed, install the coolant inlet (2) and outlet (3) hoses to the engine oil cooler (1).
  19. Install the oil cooler heat shield (4) with three bolts (5) tightened to the proper torque specification. Refer to (TORQUE SPECIFICATIONS ).
    GC0169919Courtesy of CHRYSLER GROUP, LLC
  20. Lubricate the oil filter gasket with clean engine oil.
  21. Install the oil filter (1) until the gasket contacts base. Tighten the oil filter to the proper torque specification. Refer to (TORQUE SPECIFICATIONS ).
  22. Install a new rear crankshaft oil seal. Refer to INSTALLATION  .
  23. Install the exhaust manifold, flexplate and transmission to the engine and install the engine in the vehicle. Refer to INSTALLATION  .
  24. Fill the engine crankcase with the proper oil to the correct level. Refer to ENGINE/LUBRICATION/OIL - STANDARD PROCEDURE .
  25. Fill the transmission to the proper level with the specified fluid. Refer to TRANSMISSION FILL .
  26. Fill the cooling system. Refer to 2.4L COOLANT FILL .
  27. Connect the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector to the negative battery cable.
  28. Evacuate and charge the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE .
  29. Start engine and check for leaks.
  30. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to ADDING ADDITIONAL COOLANT .
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