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Disassembly And Reassembly Following Inspection - 2.4L: Reassembly

  1. Wash and inspect the disassembled components.
  2. Install the engine block on the maintenance stand.
  3. Install the water and oil galley plugs to the engine block, using appropriate tools.
  4. Lubricate all internal engine components with clean engine oil.
    GC0103050Courtesy of CHRYSLER GROUP, LLC
  5. Install the piston oil cooler jets (2) with the bolt (1) tightened to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0164649Courtesy of CHRYSLER GROUP, LLC
  6. Measure the flatness of the cylinder head mounting surface of the engine block using a straight edge (1a) and a feeler gauge (1b) and compare it to the specification. Refer to TECHNICAL SPECIFICATIONS .
    NOTE:

    If the flatness is not within proper specification, resurface the cylinder head mounting surface.

  7. Measure the diameter of the cylinder bores and compare it to the specification. Refer to TECHNICAL SPECIFICATIONS .
    NOTE:

    If the diameters are not within proper specification, bore the cylinders to the appropriate oversize.

    NOTE:

    In the case of refinishing, all cylinders bores must undergo the same increase.

  8. Measure the roundness of the cylinder bores and compare it to the specification. Refer to TECHNICAL SPECIFICATIONS .
    NOTE:

    If the roundness is not within proper specification, bore the cylinders to the appropriate oversize.

    NOTE:

    In the case of refinishing, all cylinders bores must undergo the same increase.

  9. Measure the taper of the cylinder bores and compare it to the specification. Refer to TECHNICAL SPECIFICATIONS .
    NOTE:

    If the taper is not within proper specification, bore the cylinders to the appropriate oversize.

    NOTE:

    In the case of refinishing, all cylinders bores must undergo the same increase.

  10. Measure the crankshaft main bearing journal diameters and verify that they are within proper specification. Refer to TECHNICAL SPECIFICATIONS .
  11. If the crankshaft main bearing journal diameters do not fall within the proper specifications, correct by refinishing the diameter of the journal to the appropriate undersize.
    NOTE:

    The crankshaft has a nitride treatment; Therefore, after refinishing the crankshaft should again be nitrided and subjected to a subsequent dimensional inspection.

  12. Measure the crankshaft rod bearing journal diameters and verify that they are within proper specification. Refer to TECHNICAL SPECIFICATIONS .
  13. If the crankshaft rod bearing journal diameters do not fall within the proper specifications, correct by refinishing the diameter of the journal to the appropriate undersize.
    NOTE:

    The crankshaft has a nitride treatment; Therefore, after refinishing the crankshaft should again be nitrided and subjected to a subsequent dimensional inspection.

  14. Select main bearings to achieve the proper bearing clearance. Do not attempt to perform any adaptation to the bearing shells. If you encounter any scratches or traces of engagement, replace the bearing shells.
    GC0098631Courtesy of CHRYSLER GROUP, LLC
  15. If removed, install the target wheel to the crankshaft with four new screws. Ensure the threaded holes in the crankshaft are free of residual thread lock adhesive. Tighten the screws in the sequence shown in illustration to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0098630Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The upper main bearing shells (2) have oil lubrication holes, the lower main bearing shells (1) do not. Crankshaft thrust washers (3) are located on the second main bearing journal.

  16. Lubricate the upper main bearing shells with clean engine oil and install the upper main bearing shells and crankshaft into the engine block.
    17. NOTE:

    The thrust bearings must be installed with the notches facing the crankshaft.

  17. When installing thrust bearings at the second main bearing location, use the following procedure:
    • Move the crankshaft forward to the limit of travel. Lubricate and install the front thrust bearing by rolling the bearing onto the machined shelf between the second upper main bulk head and crankshaft thrust surface.
    • Move the crankshaft rearward to the limit of travel. Lubricate and install the rear thrust bearing by rolling the bearing onto the machined shelf between the second upper main bulk head and crankshaft thrust surface.
    GC0121382Courtesy of CHRYSLER GROUP, LLC
  18. Remove oil film from the surface to be checked by the use of Plastigage or equivalent. Plastigage is soluble in oil.
  19. Place a piece of Plastigage (1) across the entire width of the bearing journal (2). In addition, suspected areas can be checked by placing the Plastigage in the suspected area. Plastigage must not crumble in use. If brittle, obtain fresh stock.
    NOTE:

    DO NOT rotate the crankshaft. Plastigage will smear, causing inaccurate results.

  20. Install the lower main bearing shells into the main bearing caps.
  21. Install the main bearing caps with the main bearing cap bolts. Use the temporarily installed main bearing cap bolts (M10 x 1.25 x 76.5) at the No. 2, 3 and 5 main bearing caps in place of the bearing beam for this dimensional check.
    Fig 1: Ten Main Bearing Cap Bolts Tightening Sequence
    GC0162220Courtesy of CHRYSLER GROUP, LLC
  22. Tighten the ten main bearing cap bolts in the sequence shown in illustration, following this 3 step torque plus angle method. Tighten according to the following torque values:
    • Step 1: All to 15 N.m (11 ft. lbs.)
    • Step 2: All to 45 N.m (33 ft. lbs.)
    • Step 3: All an additional 45° Turn Do not use a torque wrench for this step. 
    GC0164259Courtesy of CHRYSLER GROUP, LLC
  23. Remove the main bearing caps and using a graduated measuring guide (1) determine the bearing clearance indicated by the Plastigage.
  24. Perform the measurement on the remaining journals taking care not to rotate the crankshaft.
  25. After verifying all main bearing clearances are within proper specification, lubricate and reinstall the main bearing caps with the main bearing cap bolts only hand tight at this time.
    GC0163071Courtesy of CHRYSLER GROUP, LLC
  26. Check that the thickness of the piston rings are within proper specification. Refer to TECHNICAL SPECIFICATIONS .
  27. Insert the piston rings (1a) in the cylinder bore and using a feeler gauge (1b), check that the end gaps are within proper specification. Refer to TECHNICAL SPECIFICATIONS .
    NOTE:

    Piston rings not within proper specification should be replaced.

    GC0163695Courtesy of CHRYSLER GROUP, LLC
  28. Using a feeler gauge (1a), check that the axial clearance between the rings (1b) and ring grooves on the piston are within proper specification. Refer to TECHNICAL SPECIFICATIONS .
    29. NOTE:

    Measure 9 mm up from the bottom edge of the piston skirt, perpendicular to the piston pin bore.

  29. Using a feeler gauge, check that the piston to cylinder bore clearances are within proper specification. Refer to TECHNICAL SPECIFICATIONS .
  30. Verify that the diameter of the connecting rod big end is within proper specification. Refer to TECHNICAL SPECIFICATIONS .
  31. Install the piston rings on the pistons. Refer to RING(S), PISTON, REMOVAL AND INSTALLATION .
    GC0163128Courtesy of CHRYSLER GROUP, LLC
  32. Install the rod and piston complete with bearing shell using a ring compressor (1).
    GC0165931Courtesy of CHRYSLER GROUP, LLC
  33. The pistons crowns are stamped with an arrow (1). The piston and connecting rod assemblies must be installed so the arrow points toward the front of the engine.
    GC0164963Courtesy of CHRYSLER GROUP, LLC
  34. Check that the components are free of burrs, stamps, scratches or any other surface defects. Thoroughly clean and dry the pieces before assembly.
  35. Apply the Plastigage across the surface of the rod bearing journals (1).
    36. NOTE:

    The connecting rod caps must be assembled so that the number stamped on them is facing the same side as the one stamped on the big end.

  36. Fit the bearing caps complete with bearing shells and tighten the bearing cap bolts to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0163257Courtesy of CHRYSLER GROUP, LLC
  37. Remove the bearing caps previously installed and using the graduated measuring guide (1) determine the bearing clearance indicated by the Plastigage.
  38. Perform the measurement on the remaining journals taking care not to rotate the crankshaft.
    NOTE:

    If the measured value is not within proper specification, replace the bearing shells with the proper dimension.

    CAUTION:

    The connecting rod bolts must not be reused. Always replace the connecting rod bolts whenever they are loosened or removed.

  39. Lubricate the rod bearing surface with clean engine oil. Fit all bearing caps complete with bearing shells and tighten all bearing cap bolts to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0104468Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    The main bearing cap bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced.

  40. After verifying all main and rod bearing clearances are within proper specification, check the main bearing cap bolts for necking by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) the bolt must be replaced.
    GC0169583Courtesy of CHRYSLER GROUP, LLC
  41. Remove the temporarily installed main bearing cap bolts from main bearing caps 2, 3 and 5. Install the bearing beam (1) with its longer bolts so that the <FRT indication (2) is pointing to the front of the engine.
    GC0162220Courtesy of CHRYSLER GROUP, LLC
  42. Tighten the ten main bearing cap bolts in the sequence shown in illustration, following this 3 step torque plus angle method. Tighten according to the following torque values:
    • Step 1: All to 15 N.m (11 ft. lbs.)
    • Step 2: All to 45 N.m (33 ft. lbs.)
    • Step 3: All an additional 45° Turn Do not use a torque wrench for this step. 
    GC0081626Courtesy of CHRYSLER GROUP, LLC
  43. Measure the crankshaft end play and compare it to the specification. Refer to TECHNICAL SPECIFICATIONS .
    NOTE:

    Crankshaft thrust bearings are not selectable and are only available in a single thickness.

    GC0121276Courtesy of CHRYSLER GROUP, LLC
  44. 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 the proper specification within the next 10 minutes. Prolonged exposure to the air prior to assembly may result in engine fluid leakage.

  45. Apply a 2 mm bead of Mopar® Engine Sealant RTV Silicone Rubber Adhesive as shown in illustration.
    Fig 2: Ladder Frame Bolts Tightening Sequence
    GC0121277Courtesy of CHRYSLER GROUP, LLC
  46. 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.).
    GC0169512Courtesy of CHRYSLER GROUP, LLC
  47. If removed, install the crankshaft sprocket key (2) in the crankshaft.
  48. Install the crankshaft sprocket (1).
    GC0169024Courtesy of CHRYSLER GROUP, LLC
  49. Align the timing chain onto the crank sprocket mark (2) using the painted link (1) as a guide.
    GC0084105Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    The balance shaft/oil pump assembly bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced.

  50. Check the balance shaft/oil pump bolts for necking by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) the bolt must be replaced.
    GC0165462Courtesy of CHRYSLER GROUP, LLC
  51. Align the timing chain onto the balance shaft/oil pump sprocket mark using the painted link (1) as a guide.
  52. With the rear of the balance shaft/oil pump assembly on a slight angle, position the gear into the chain links and install the balance shaft/oil pump assembly on the ladder frame. Make sure the paint marks are aligned.
    Fig 3: Balance Shaft/Oil Pump Bolts Tightening Sequence
    GC0082446Courtesy of CHRYSLER GROUP, LLC
  53. Install the four balance shaft/oil pump bolts finger tight.
  54. Tighten the balance shaft/oil pump bolts in the sequence shown in illustration, following the 3 step torque plus an ending torque angle method. Tighten according to the following torque values:
    • Step 1: All to 15 N.m (11 ft. lbs.)
    • Step 2: All to 29 N.m (22 ft. lbs.)
    • Step 3: All an additional 90° Do not use a torque wrench for this step. 
    GC0084902Courtesy of CHRYSLER GROUP, LLC
  55. Reset the balance shaft/oil pump chain tensioner by pushing the plunger inward and installing a pin to hold the plunger in the retracted position.
    GC0169019Courtesy of CHRYSLER GROUP, LLC
  56. Install the fixed chain guide (7) with two bolts (6) tightened to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  57. Install the tensioner arm (1) with the bolt (2) tightened to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  58. Install the tensioner (4) with the two bolts (5) tightened to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  59. Remove the tensioner pin (3) from the tensioner (4).
    GC0164047Courtesy of CHRYSLER GROUP, LLC
  60. Install the splash shield (1) and tighten the bolts to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0164851Courtesy of CHRYSLER GROUP, LLC
  61. Using the C-4171, special tool (#9706, Installer, Crankshaft Rear Oil Seal) and special tool (#9509, Installer, Oil Seal) (1), install a new rear crankshaft oil seal.
    GC0169431Courtesy of CHRYSLER GROUP, LLC
  62. If equipped, install the intermediate shaft bearing housing (1) with three bolts (2) tightened to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0169244Courtesy of CHRYSLER GROUP, LLC
  63. If removed, install a NEW  gasket (1) onto the water pump.
    GC0166167Courtesy of CHRYSLER GROUP, LLC
  64. If removed, install the water pump. Tightened the five bolts (1) in a criss-cross pattern to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0165491Courtesy of CHRYSLER GROUP, LLC
  65. Using a NEW  gasket, install the water pump body (1a). Tighten the bolts (1b) to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
  66. Install the nuts (2) securing the coolant tube to the water pump body (1b) and tighten to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
  67. Install the oil pressure sensor and tighten to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  68. Install the crankshaft position (CKP) sensor and tighten the mounting bolt to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  69. Install the knock sensor with a new mounting bolt tightened to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0165547Courtesy of CHRYSLER GROUP, LLC
  70. Install the motor oil cooler, engaging the reference centering with the tab (a) shown in illustration and tighten the union.
  71. Install the heat shield and tighten the screws.
  72. Lubricate the seal with engine oil and mount the engine oil filter tightening it completely by hand.
  73. Connect the water flow and return pipes to the engine oil cooler and tighten the clamps.
    GC0169127Courtesy of CHRYSLER GROUP, LLC
  74. Install the Variable Valve Actuation Assembly (VVAA) oil supply filter (1) in the engine block.
    GC0164674Courtesy of CHRYSLER GROUP, LLC
  75. Position the cylinder head gasket engaging the centering bushings.
  76. Place sealant on the cylinder head gasket at the points indicated (1) in the figure.
    GC0121234Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced.

  77. Check the cylinder head bolts for necking by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) the bolt must be replaced.
    Fig 4: Cylinder Head Bolts Tightening Sequence
    GC0163176Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Before installing the cylinder head bolts, lubricate the threads with clean engine oil.

  78. Install all cylinder head bolts finger tight.
  79. Tighten the cylinder head bolts in the sequence shown in illustration, following this 4 step torque plus angle method. Tighten according to the following torque values:
    • Step 1: All to 10 N.m (7 ft. lbs.)
    • Step 2: All to 16 N.m (12 ft. lbs.)
    • Step 3: All to 35 N.m (26 ft. lbs.)
    • Step 4: All an additional 160° ± 2° Do not use a torque wrench for this step. 
      GC0163524Courtesy of CHRYSLER GROUP, LLC
  80. Install the hydraulic tappets (1).
    GC0165519Courtesy of CHRYSLER GROUP, LLC
  81. Install the camshaft (1) into the cylinder head.
  82. Install the bearing caps (2), respecting the numbering of the cylinders stamped at the top of each cap, and tighten the camshaft cap to cylinder head bolts to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    NOTE:

    The arrow on the bearing cap "a" must point to the timing side.

    GC0164745Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    During all the handling operations, the MULTIAIR actuator should not be overturned with hydraulic tappets above.

  83. Install a NEW  metal gasket on the cylinder head top.
  84. Position the MULTIAIR actuator onto the cylinder head and tighten the front MULTIAIR actuator to cylinder head bolts to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  85. Remove the special tool (#10259B, Compressor, MultiAir® Spring) from the MULTIAIR actuator.
  86. Install and tighten the rear MULTIAIR actuator to cylinder head bolts to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0163135Courtesy of CHRYSLER GROUP, LLC
  87. Clean the gasket mating surfaces.
  88. Install a NEW  thermostat housing gasket (1).
    GC0163402Courtesy of CHRYSLER GROUP, LLC
  89. Install the thermostat housing (1) and tighten bolt finger tight.
    GC0165896Courtesy of CHRYSLER GROUP, LLC
  90. Install the vacuum pump support bracket (1b) and securely tighten fasteners (1a).
    GC0163577Courtesy of CHRYSLER GROUP, LLC
  91. Tighten the thermostat housing bolts (1) in a criss-cross pattern to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0165638Courtesy of CHRYSLER GROUP, LLC
  92. Install the bolt (1b) securing the coolant tube to the thermostat housing and tighten to the proper torque specification then bend lock tab to secure bolt (1a). Refer to TECHNICAL SPECIFICATIONS .
    GC0169101Courtesy of CHRYSLER GROUP, LLC
  93. Install the timing chain guide (1) with three bolts (2) tightened to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  94. Install the tensioner arm (4) with the bushing and bolt (3) tightened to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0163893Courtesy of CHRYSLER GROUP, LLC
  95. Verify that the crankshaft key is in the "9 o'clock" in correspondence with the surfaces of contact between the lower and upper crankcase.
  96. Install the chain, align the drive gear with the painted link. If you mount a new chain, the alignment reference is yellow.
    GC0165239Courtesy of CHRYSLER GROUP, LLC
  97. Check that the alignment mark (1) is in the "12 o'clock" position.
    GC0165600Courtesy of CHRYSLER GROUP, LLC
  98. Fit the chain on the camshaft sprocket by matching the gear notch (1a) with the marked link (1b). If you mount a new chain, the alignment reference is yellow.
  99. Align the pin (2) and install the camshaft sprocket.
    GC0166199Courtesy of CHRYSLER GROUP, LLC
  100. Tighten the camshaft sprocket bolt (1) to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0163736Courtesy of CHRYSLER GROUP, LLC
  101. Disengage the pawl (1a) from the rack, compress the piston (1b) and insert the pin lock (1c).
    GC0165061Courtesy of CHRYSLER GROUP, LLC
  102. Install the tensioner (1) and tighten the screws to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  103. Remove the locking plunger pin (2).
    GC0165102Courtesy of CHRYSLER GROUP, LLC
  104. Apply a suitable silicone sealant to the engine timing cover to engine block gasket surface (1) as shown in illustration.
    GC0165810Courtesy of CHRYSLER GROUP, LLC
  105. Apply a bead (2 mm) of a suitable silicone sealant (1a) and (1b) to the surfaces indicated in the figure.
    GC0164656Courtesy of CHRYSLER GROUP, LLC
  106. Install the engine timing cover and tighten the mounting bolts (1) to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0164304Courtesy of CHRYSLER GROUP, LLC
  107. Apply a 2 mm bead of Mopar® Engine Sealant RTV Silicone Rubber Adhesive around the oil pan as shown in illustration.
    GC0165103Courtesy of CHRYSLER GROUP, LLC
  108. Install the oil pan and tighten the bolts (1) to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  109. Install the A/C compressor mounting bracket and tighten the bolts (2) to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0165067Courtesy of CHRYSLER GROUP, LLC
  110. Install the A/C compressor with three bolts (1) and tighten the bolts to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0163703Courtesy of CHRYSLER GROUP, LLC
  111. Install a new front crankshaft oil seal with the special tool (#9506, Installer, Oil Seal) tool (1).
    GC0169358Courtesy of CHRYSLER GROUP, LLC
  112. Install the generator mounting bracket (1) with three bolts (2) tightened to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0165128Courtesy of CHRYSLER GROUP, LLC
  113. If removed, install the accessory drive belt tensioner (1) and tighten the bolts to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0166120Courtesy of CHRYSLER GROUP, LLC
  114. Install the accessory drive belt idler pulley (1) and tighten the bolt to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0165695Courtesy of CHRYSLER GROUP, LLC
  115. Install the water pump pulley (1a). Tighten the three bolts (1b) to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0164247Courtesy of CHRYSLER GROUP, LLC
  116. Install the vibration damper onto the crankshaft (1c).
  117. Using the special tool (#9707, Holder, Vibration Damper) (1a), Install the vibration damper bolt (1b) and tighten to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0163299Courtesy of CHRYSLER GROUP, LLC
  118. Install the alternator, engaging the centering bushing and tighten the bolts (1) to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
  119. Connect the alternator wiring with the nut (3) and engage the cap (3).
  120. Connect the wire harness connector (2) to the alternator.
    GC0163563Courtesy of CHRYSLER GROUP, LLC
  121. Install the wiring retaining bracket to the cylinder head with the screw (1) tighten to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0165917Courtesy of CHRYSLER GROUP, LLC
  122. Rotate the belt tensioner (1b) and install the serpentine belt (1c).
    GC0165710Courtesy of CHRYSLER GROUP, LLC
  123. Install new seals on the cylinder head cover.
    GC0163546Courtesy of CHRYSLER GROUP, LLC
  124. Apply sealant in the points shown in illustration (1).
    Fig 5: Cylinder Head Cover Bolts Tightening Sequence
    GC0163584Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Place the stud-bolts in the positions previously marked for installation.

  125. Install the cylinder head cover and tighten the bolts in the order shown in illustration to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0165511Courtesy of CHRYSLER GROUP, LLC
  126. Install the ignition coils (1) and tighten the screws (1) to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  127. Using NEW  gaskets, install the intake manifold and tighten the fasteners to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  128. Install the intake manifold support bracket nuts and tighten to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  129. Install the intake manifold lower support bracket bolt and tighten to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  130. Install the intake manifold silencer cover and securely tighten the four screws.
  131. Install the fuel rail with injectors and securely tighten the retaining screws.
  132. Install the fuel vapor solenoid.
  133. Connect the fuel vapor delivery pipe to the air box.
  134. Install the sound absorber.
  135. Install a new gasket on the inlet plenum.
  136. Install the throttle body, positioning it correctly on the centering pins.
  137. Install the throttle body fasteners and tighten to the proper torque specification. Refer to FUEL INJECTION, GAS, TECHNICAL SPECIFICATIONS .
  138. Install the throttle body reinforcement bracket and tighten the fastener to the proper torque specification. Refer to FUEL INJECTION, GAS, TECHNICAL SPECIFICATIONS .
    GC0165500Courtesy of CHRYSLER GROUP, LLC
  139. Connect the hose (1) to the Positive Crankcase Ventilation (PCV) valve.
    GC0169552Courtesy of CHRYSLER GROUP, LLC
  140. Install new vacuum pump O-ring seals (1, 2).
    GC0169012Courtesy of CHRYSLER GROUP, LLC
  141. Install the vacuum pump into the cylinder head opening with two bolts (1) tightened to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0169172Courtesy of CHRYSLER GROUP, LLC
  142. Install the oil dipstick tube (1) to the engine with the bolt (2) tightened to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0164712Courtesy of CHRYSLER GROUP, LLC
  143. Install the ignition capacitor (1) and tighten the stud-bolt securely.
    GC0163622Courtesy of CHRYSLER GROUP, LLC
  144. Install the ignition capacitor heat shield (1) and tighten the nut securely.
  145. Position the wire harness on the engine and make the following connections:
    • Install the screws securing the wiring duct on the intake side.
    • Install the screws securing the wiring duct on the exhaust side.
    • Connect the knock sensor wire harness connector
    • Connect the crankshaft position sensor wire harness connector
    • Connect the A/C compressor wire harness connector
    • Connect the manifold pressure and temperature sensor wire harness connector and engage the retaining clips
    • Connect the engine oil pressure sensor wire harness connector
    • Connect the throttle body wire harness connector
    • Connect the coolant temperature sensor wire harness connector
    • Connect the purge solenoid wire harness connector
    • Connect the fuel injector wire harness connectors
    • Connect the engine oil temperature sensor wire harness connector
    • Connect the variable valve actuator wire harness connectors
    • Connect the ignition coil wire harness connectors
    • Connect the ignition capacitor wire harness connector
  146. Install a new oil drain plug and tighten to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  147. Service the engine with the proper quality and quantity of engine oil. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
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