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2.4L Engine (Service Information): 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).
    GC0160116Courtesy of CHRYSLER GROUP, LLC
  2. Push the transmission (3) against the engine (1) until the guide pins engage.
  3. Install the transmission bolts (2) and tighten to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
  4. On vehicles equipped with an automatic transaxle, install torque converter bolts.
    GC0160135Courtesy of CHRYSLER GROUP, LLC
  5. 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.

  6. Tighten all the torque converter bolts to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
    GC0171533Courtesy of CHRYSLER GROUP, LLC
  7. Install the torque converter bolt access door (1) and tighten the bolt (2) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
    GC0171474Courtesy of CHRYSLER GROUP, LLC
  8. 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.
  9. Install the right engine mount insulator. Refer to INSTALLATION  .
  10. Install the left engine mount insulator. Refer to INSTALLATION  .
  11. Remove the strap (1) and the power train dolly (3).
    GC0159736Courtesy of CHRYSLER GROUP, LLC
  12. Connect the shifter cable (2) to the transmission.
    GC0155680Courtesy of CHRYSLER GROUP, LLC
  13. Install the ground cable (2) to transaxle with the bolt (1) tightened to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
  14. Install the exhaust manifold/catalytic converter. Refer to INSTALLATION  .
  15. Install the starter motor. Refer to 2.4L .
  16. Install the Power Transfer Unit (PTU), if equipped. Refer to INSTALLATION .
  17. Install the front suspension crossmember. Refer to INSTALLATION .
  18. Install the rear engine mount insulator. Refer to INSTALLATION  .
  19. Install the exhaust cross-under pipe assembly. Refer to PIPE, EXHAUST CROSSUNDER, INSTALLATION .
  20. Install the propeller shaft, if equipped. Refer to INSTALLATION .
    GC0152879Courtesy of CHRYSLER GROUP, LLC
  21. Install the front fascia support beams (1) and tighten the bolts to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
    GC0155722Courtesy of CHRYSLER GROUP, LLC
  22. Install the right and left lower bumper reinforcement (1) and front fascia support beams to the frame/front end module and tighten the fasteners (2) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
    GC0156438Courtesy of CHRYSLER GROUP, LLC
  23. Install the crossmember to fascia support beam brackets and tighten the bolts (1) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
  24. Install the front tow hooks. Refer to INSTALLATION .
  25. Install the battery tray. Refer to TRAY, BATTERY, INSTALLATION .
    GC0160008Courtesy of CHRYSLER GROUP, LLC
  26. Install the bolt (2) holding the windshield washer reservoir to the battery tray.
  27. Insert the harness retainer (1) to the battery tray.
  28. Install the front fascia assembly. Refer to FASCIA, FRONT, INSTALLATION .
  29. Install the left wheel well liner. Refer to INSTALLATION .
  30. Install the skid plate (if equipped). Refer to PLATE, SKID, SIDE, INSTALLATION .
  31. Install the front wheels. Refer to INSTALLATION .
  32. Install the engine wire harness retainers.
    GC0159945Courtesy of CHRYSLER GROUP, LLC
  33. Connect the transmission cooler hoses (1) at the transmission fittings.
    GC0155678Courtesy of CHRYSLER GROUP, LLC
  34. Install the coolant reservoir return hose assembly (2) Install the hose bolts (1). Connect both ends of the pipe.
    GC0169946Courtesy of CHRYSLER GROUP, LLC
  35. Connect the wire harness connector (2) to the Manifold Air Pressure (MAP) sensor (1).
    GC0169915Courtesy of CHRYSLER GROUP, LLC
  36. Connect the wire harness connector (2) to the oil temperature sensor (1).
    GC0169971Courtesy of CHRYSLER GROUP, LLC
  37. Install the fuel injector insulator (3).
  38. Connect the fuel line (1) and the purge line (2) quick connect couplings.
    GC0159705Courtesy of CHRYSLER GROUP, LLC
  39. Install the air conditioning compressor (2) and tighten the bolts (1) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
    GC0159412Courtesy of CHRYSLER GROUP, LLC
  40. Connect the air conditioning compressor electrical connectors (1).
    GC0159214Courtesy of CHRYSLER GROUP, LLC
  41. Install the generator (2) to the bracket (3) and tighten the bolts (1) to the proper torque specification. Refer to (TORQUE SPECIFICATIONS ).
    GC0160154Courtesy of CHRYSLER GROUP, LLC
  42. Install the generator electrical connectors (1 & 2).
  43. Install the nut (1) and tighten to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
  44. Close the 12 volt protective cover (3).
  45. Install the serpentine belt. Refer to BELT, SERPENTINE, INSTALLATION .
    GC0172043Courtesy of CHRYSLER GROUP, LLC
  46. 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
  47. 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).
  48. Install the air cleaner body. Refer to INSTALLATION  .
  49. Install the clean air hose. Refer to HOSE, CLEAN AIR, INSTALLATION .
    GC0160073Courtesy of CHRYSLER GROUP, LLC
  50. Install the radiator upper closeout panel push pins (2).
  51. Install the radiator upper closeout panel bolts (4).
  52. Install the radiator upper closeout panel bolts (3).
  53. Install the Power Distribution Center (PDC). Refer to CENTER, POWER DISTRIBUTION (PDC), INSTALLATION .
    GC0162323Courtesy of CHRYSLER GROUP, LLC
  54. Place the ground cable and the wiring harness bracket in position on the transmission.
  55. 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 .
    GC0172072Courtesy of CHRYSLER GROUP, LLC
  56. Connect the heater core supply (1) and return (2) hoses at the fittings nearest the thermostat housing.
    GC0159726Courtesy of CHRYSLER GROUP, LLC
  57. Install the Powertrain Control Module (PCM) bracket (3) to the battery tray (1). Install the PCM mount bracket bolts (2 & 4).
  58. Install the PCM. Refer to MODULE, POWERTRAIN CONTROL (PCM), INSTALLATION .
    GC0159342Courtesy of CHRYSLER GROUP, LLC
  59. Install the battery (2). Refer to BATTERY, INSTALLATION .
  60. Connect the battery cables (1 & 3). If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector to the negative battery cable.
    GC0159694Courtesy of CHRYSLER GROUP, LLC
  61. Install the battery cover (1).
  62. Fill the cooling system. Refer to 2.4L COOLANT FILL .
    GC0084367Courtesy of CHRYSLER GROUP, LLC
  63. Install the steering coupler bolt (3) and tighten to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0159679Courtesy of CHRYSLER GROUP, LLC
  64. Install the engine cover (1) to the ball studs (2).
  65. Add engine oil and transmission fluid as necessary.
  66. Start engine, check for leaks.
  67. Bleed the cooling system. Refer to COOLANT SYSTEM AIR EVACUATION .
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 POWERTRAIN VERIFICATION TEST .

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