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2.4L MULTIAIR: Installation

WARNING: This page is about a different variant/trim than selected.
GC0164099Courtesy of CHRYSLER GROUP, LLC
  1. If removed, install the Power Transfer Unit (PTU) actuator (1b) and tighten the bolts (1a) to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0163534Courtesy of CHRYSLER GROUP, LLC
  2. Install the PTU (1a) complete with a NEW  O-ring and loosely install the PTU bolts.
    GC0199717Courtesy of CHRYSLER GROUP, LLC
  3. Inspect the end of the quill shaft (2) through the weep hole (1) in the PTU. There should be a 3mm gap of empty space between the end of the shaft (2) and the edge of the hole if the quill shaft is pushed in completely. Failure to install the quill shaft completely will lead to a transmission fluid leak from the PTU weep hole.
    GC0165499Courtesy of CHRYSLER GROUP, LLC
  4. Install the intake manifold support bracket stud (1) into the intake manifold.
    GC0163534Courtesy of CHRYSLER GROUP, LLC
  5. Tighten the PTU bolts (1b) to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0163460Courtesy of CHRYSLER GROUP, LLC
  6. Install the engine mount to transmission bracket bolt (1) and tighten to the proper torque specification. Refer to (TORQUE SPECIFICATIONS ).
  7. Install the PTU vent tube.
    GC0164532Courtesy of CHRYSLER GROUP, LLC
  8. Install the PTU support bracket (1a) the tighten the bolts (1b) and (1c) to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0166153Courtesy of CHRYSLER GROUP, LLC
  9. Install the intake manifold support bracket and tighten the nuts (2) to the proper torque specification. Refer to (TORQUE SPECIFICATIONS ).
  10. Connect the PTU actuator wire harness connector (1).
    GC0163806Courtesy of CHRYSLER GROUP, LLC
  11. Position the exhaust pipe in place, install the nuts (3) and tighten to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
  12. Install the exhaust pipe support bracket bolt (2) and tighten to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
  13. Install the front exhaust pipe support bracket bolts (1) and tighten to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
  14. Install the rear propeller shaft. Refer to REMOVAL AND INSTALLATION .
  15. Install the right front half shaft. Refer to REMOVAL AND INSTALLATION or REMOVAL AND INSTALLATION .
  16. Verify that the PTU and transmission are filled to the specified fluid level. Refer to STANDARD PROCEDURE .
  17. Remove the support and lower the vehicle.
  18. Connect the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector to the negative battery cable.
  19. When installing a NEW  (PTU), connect the diagnostic scan tool, enter "miscellaneous functions" of the DriveTrain Control Module (DTCM) and run the self-learning procedure for the PTU.
  20. Road test the vehicle to verify the repair.
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