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Installation - Engine Assembly

Fig 1: Positioning Engine Cradle Support Post
GC0021170Courtesy of DAIMLERCHRYSLER CORP.
1 - POST LOCATING HOLES IN BLOCK
2 - POST POSITIONED UNDER BRACKET
3 - POST LOCATING HOLE IN STRUT
4 - SAFETY STRAPS
5 - FLOOR JACK
6 - POST KIT ENGINE CRADLE 6848
7 - DOLLY 6135
8 - CRADLE 6710
  1. Position engine and transmission assembly under vehicle and slowly lower the vehicle over the engine/transaxle assembly.
    Fig 2: Right Mount Through Bolt
    GC0021168Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOLT
    2 - RIGHT ENGINE MOUNT
    3 - ENGINE MOUNT BRACKET
    NOTE: To prevent possible damage to engine mount bracket (3) or mount (2), the through bolt (1) must be started by hand to prevent cross threading.
  2. Continue lowering vehicle until engine/transaxle aligns to mounting locations. Install mounting bolts at the right engine mount. Tighten bolts (1) to 118 N.m (87 ft. lbs.).
    Fig 3: Left Mount & Bolt
    GC0021169Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOLT
    2 - TRANSAXLE
    3 - LEFT MOUNT
  3. Install left transaxle mount (3). Tighten bolts (1) to 118 N.m (87 ft. lbs.).
  4. Install upper engine torque strut.
    Fig 4: Positioning Engine Cradle Support Post
    GC0021170Courtesy of DAIMLERCHRYSLER CORP.
    1 - POST LOCATING HOLES IN BLOCK
    2 - POST POSITIONED UNDER BRACKET
    3 - POST LOCATING HOLE IN STRUT
    4 - SAFETY STRAPS
    5 - FLOOR JACK
    6 - POST KIT ENGINE CRADLE 6848
    7 - DOLLY 6135
    8 - CRADLE 6710
  5. Remove safety straps (4) from engine/transaxle assembly. Slowly raise vehicle enough to remove the engine dolly 6135 (7) and cradle 6710 (8).
    Fig 5: Pressure Hose Connection To Pump
    GC0042759Courtesy of DAIMLERCHRYSLER CORP.
    1 - PUMP
    2 - PRESSURE HOSE
  6. Install power steering pump (1).
  7. Connect power steering lines (2) to power steering pump (1).
  8. Install A/C compressor.
    Fig 6: View Of Pencil Strut Mounting
    GC0042760Courtesy of DAIMLERCHRYSLER CORP.
    1 - NUT
    2 - PENCIL STRUT
    3 - NUT
    4 - FLAT WASHER
    5 - LOWER TORQUE STRUT
  9. Install lower engine torque strut (5) (Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - INSTALLATION) .
  10. Automatic Transmission equipped vehicles: 
    • Install torque converter bolts.
  11. Manual Transmission equipped vehicles: 
    • Install drive plate to clutch module bolts.
    Fig 7: Structural Collar and Bending Strut - (Manual Transaxle Equipped)
    GC0042764Courtesy of DAIMLERCHRYSLER CORP.
    1 - HYDRAULIC CLUTCH SLAVE CYLINDER
    2 - TRANSAXLE
    3 - POWER STEERING HOSE
    4 - STRUCTURAL COLLAR
  12. Install structural collar (4) (Refer to ENGINE/ENGINE BLOCK/STRUCTURAL COLLAR - INSTALLATION) .
    Fig 8: Turbocharger Brackets And Heat Shields
    GC0019350Courtesy of DAIMLERCHRYSLER CORP.
    1 - UPPER/LOWER HEAT SHIELDS
    2 - TURBOCHARGER SUPPORT BRACKET
    3 - ELBOW
    4 - ELBOW SUPPORT BRACKET
  13. Turbocharger equipped vehicles:   Install elbow (3), turbocharger support bracket (2), elbow support bracket (4), and upper and lower heat shields (1). See Fig 8.
    Fig 9: Power Steering Fluid Pressure Hose
    GC0021166Courtesy of DAIMLERCHRYSLER CORP.
    1 - STEERING GEAR
    2 - FITTING
    3 - POWER STEERING PRESSURE HOSE
  14. Non-Turbo equipped vehicles:   Connect power steering pressure hose (3) to steering gear (1). See Fig 9.
    Fig 10: Hoses At Power Steering Gear - 2.4L Turbo
    GC0021171Courtesy of DAIMLERCHRYSLER CORP.
    1 - POWER STEERING GEAR
    2 - ROUTING CLIP
    3 - PRESSURE HOSE TUBE NUT
    4 - RETURN HOSE CLAMP
    5 - PRESSURE/RETURN HOSE ASSEMBLY
  15. Turbocharger equipped vehicles:   Connect both power steering hoses (5) to steering gear (1). See Fig 10.
    Fig 11: Exhaust System To Manifold Connection
    GC0021165Courtesy of DAIMLERCHRYSLER CORP.
    1 - GASKET
    2 - CATALYTIC CONVERTER
    3 - NUT
  16. Connect exhaust system (2) to manifold.
  17. Connect the downstream oxygen sensor.
    Fig 12: Charge Air Cooler Hoses
    GC0019344Courtesy of DAIMLERCHRYSLER CORP.
    1 - HOSE - CHARGE AIR COOLER TO THROTTLE BODY
    2 - CHARGE AIR COOLER
    3 - HOSE - TURBOCHARGER TO CHARGE AIR COOLER
  18. Turbocharger equipped vehicles:   Install charge air cooler to throttle body hose (1). See Fig 12.
  19. Install charge air cooler to turbocharger hose (3). See Fig 12.
  20. Install generator and mounting brackets.
  21. Install accessory drive belts (Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION) .
    Fig 13: Splash Shield
    GC0042765Courtesy of DAIMLERCHRYSLER CORP.
    1 - RIGHT MOUNT BOLT ACCESS PLUG
    2 - FASCIA
    3 - SPLASH SHIELD
    4 - CRANKSHAFT BOLT ACCESS PLUG
  22. Install axle shafts (Refer to DIFFERENTIAL & DRIVELINE/HALF SHAFT - INSTALLATION) .
  23. Install right inner splash shield (3).
  24. Install wheels and lower vehicle.
  25. Install cooling module assembly (fan, radiator, A/C condenser, transmission oil cooler). Connect radiator fan electrical connector.
  26. Turbocharger equipped vehicles:   Connect power steering hoses to radiator.
    Fig 14: Clutch Hydraulic Line to Slave Cylinder
    GC0020072Courtesy of DAIMLERCHRYSLER CORP.
    1 - SLAVE CYLINDER
    2 - HYDRAULIC TUBE
  27. Manual Transmission equipped vehicles: 
    • Connect clutch hydraulic line (2). See Fig 14.
    • Connect transmission shift linkage.
    • Connect transmission electrical connectors.
    NOTE: It is not necessary to bleed the clutch hydraulic system. The quick-connect fittings close immediately after disconnection; allowing no fluid to escape.
  28. Automatic Transmission equipped vehicles: 
    • Connect transmission oil cooler lines using service splice kit. Refer to instructions provided with kit.
    • Connect transmission electrical connectors.
    • Connect transmission shift linkage.
    Fig 15: A/C LINES
    GC0042752Courtesy of DAIMLERCHRYSLER CORP.
    1 - A/C LINES
    2 - MAP SENSOR
    3 - OIL FILL CAP
  29. Connect A/C lines (1) at junction near upper torque strut.
  30. Connect upper A/C line to A/C condenser.
  31. Install upper and lower radiator hoses.
    Fig 16: Upper Radiator Closure Panel And Center Brace
    GC0019362Courtesy of DAIMLERCHRYSLER CORP.
    1 - UPPER RADIATOR CLOSURE PANEL
    2 - CENTER BRACE
  32. Install upper radiator closure panel (1) and center brace (2) (Refer to BODY/EXTERIOR/RADIATOR CLOSURE PANEL - INSTALLATION) . See Fig 16.
    Fig 17: GRILL REMOVAL & INSTALLATION
    GC0042757Courtesy of DAIMLERCHRYSLER CORP.
    1 - GRILL RETAINING FASTENERS
    2 - GRILL
  33. Install grille (2) and tighten grill retaining fasteners (1) (Refer to BODY/EXTERIOR/GRILLE - INSTALLATION) .
  34. Connect fuel line and heater hoses.
  35. Connect coolant reserve/recovery hose to coolant outlet connector.
  36. Connect brake booster vacuum hose to intake manifold.
  37. Connect the proportional purge hose to throttle body.
    Fig 18: PDC Bracket Attaching Bolts
    GC0021164Courtesy of DAIMLERCHRYSLER CORP.
    1 - PDC
    2 - PDC BRACKET BOLTS
    3 - BATTERY TRAY BOLT
  38. Install all ground straps and connect engine wiring harness.
  39. Position PDC (1) and install bolts Connect positive battery cable to PDC (1) and ground wire to vehicle body.
  40. Connect engine wiring harness at Powertrain Control Module (PCM).
  41. Connect throttle and speed control cables.
  42. Install battery tray and battery (Refer to ELECTRICAL/BATTERY SYSTEM/BATTERY - INSTALLATION) .
  43. Connect cables to battery.
    Fig 19: AIR CLEANER
    GC0042753Courtesy of DAIMLERCHRYSLER CORP.
    1 - THROTTLE LINKAGE COVER
    2 - AIR CLEANER
    3 - BATTERY
  44. Install air cleaner housing assembly and connect clean air hose, (Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING - INSTALLATION) .
  45. Install oil filter. Fill engine crankcase with proper oil to correct level.
  46. Fill power steering system.
  47. Fill cooling system, (Refer to FILLING COOLING SYSTEM - 2.0L/2.4L ENGINE ).
  48. Evacuate and recharge A/C system, (Refer to the appropriate procedures under PLUMBING - STANDARD PROCEDURE ).
  49. Start engine and run until operating temperature is reached. Check for leaks.
  50. Perform torque strut adjustment procedure, (Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - ADJUSTMENTS) .
  51. Adjust transmission linkage, if necessary.
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