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2.2L Turbo Diesel

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Fig 1: Transaxle Upper Mount Bracket
GC0022011Courtesy of DAIMLERCHRYSLER CORP.
1 - TRANSAXLE
2 - BRACKET
3 - BOLT
  1. Install transaxle to transmission jack and secure. Raise transaxle into position and install to engine.
  2. Install accessible bellhousing-to-block bolts.
  3. Install transaxle (1) upper mount bracket (2). See Fig 1.
  4. Install the bolts (3) to hold the upper mount bracket (2) to the transaxle (1). Tighten the bolts to 20 N.m (170 in.lbs.).
    Fig 2: Upper Mount-to-Bracket
    GC0022010Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOLT (2)
    2 - MOUNT
    3 - BRACKET
  5. Raise transaxle with jack until mount bracket (3) pilots into upper mount (2). Access engine compartment. Install and torque upper mount-to-transaxle bracket bolts (1). See Fig 2.
    Fig 3: Starter Bolt and Ground Cable
    GC0022012Courtesy of DAIMLERCHRYSLER CORP.
    1 - GROUND CABLE
    2 - BOLT
    3 - STARTER MOTOR
  6. Remove transmission jack.
  7. Install starter motor (3) into position. Install ground cable (1) and lower starter mounting bolt (2). See Fig 3.
    Fig 4: Intercooler Inlet Hose Fasteners
    GC0022009Courtesy of DAIMLERCHRYSLER CORP.
    1 - INTERCOOLER INLET HOSE
    2 - BOLTS (2)
    3 - STRUCTURAL COLLAR
  8. Install lower bellhousing bolt.
  9. Install two intercooler connector pipe-to-engine oil pan bolts (2). See Fig 4.
    Fig 5: Halfshaft And Intermediate Shaft (2.2L TD Shown - 2.4L Turbo Similar)
    GC0019626Courtesy of DAIMLERCHRYSLER CORP.
    1 - HALFSHAFT (LH)
    2 - TRANSAXLE
    3 - INTERMEDIATE SHAFT
    4 - BOLT (3)
    5 - HALFSHAFT (RH)
  10. Remove transaxle fill plug and add suitable amount of ATF+4 (Automatic Transmission Fluid-Type 9602). Torque fill plug to 39-47 N.m (29-35 ft. lbs.) (Refer to TRANSMISSION/TRANSAXLE/MANUAL/FLUID - STANDARD PROCEDURE) 
  11. Install intermediate shaft/bearing assembly (3) into position. Install and torque bearing-to-retainer bolts (4). See Fig 5.
    Fig 6: Applying Grease To Clean Face Of Outer CV Joint
    GC0041028Courtesy of DAIMLERCHRYSLER CORP.
  12. Apply a light coating of Mopar® multi-purpose wheel bearing grease around the circumference of the flat surface (1). See Fig 6. Do not apply too much grease. 
  13. Wipe the rear of the hub and bearing in the knuckle clean where they contact the C/V joint.
  14. Install halfshafts (1, 5) (Refer to DIFFERENTIAL & DRIVELINE/HALF SHAFT - INSTALLATION) .
    Fig 7: Clutch Slave Cylinder Hydraulic Connection
    GC0022008Courtesy of DAIMLERCHRYSLER CORP.
    1 - MASTER CYLINDER TUBE
    2 - SLAVE CYLINDER
  15. Lower vehicle.
  16. Connect clutch hydraulic plumbing (1) to slave cylinder (2) quick-connect. See Fig 7. An audible "click" should be heard. Verify connection by pulling outward.
    Fig 8: VSS and Back-Up Lamp Switches
    GC0022007Courtesy of DAIMLERCHRYSLER CORP.
    1 - BACK-UP LAMP SWITCH
    2 - VEHICLE SPEED SENSOR (VSS)
  17. Connect vehicle speed sensor connector (2). See Fig 8.
  18. Connect back-up lamp switch connector (1). See Fig 8.
    Fig 9: Power Steering Reservoir
    GC0022006Courtesy of DAIMLERCHRYSLER CORP.
    1 - RESERVOIR
    2 - BOLT
  19. Install power steering reservoir (1) into position and torque bolts (2). See Fig 9.
    Fig 10: Gear Shift Cables and Bracket at Transaxle
    GC0022005Courtesy of DAIMLERCHRYSLER CORP.
    1 - TRANSAXLE
    2 - GEAR SHIFT CABLE BRACKET
    3 - BOLT (3)
    4 - CABLE ASSEMBLY
    5 -CLIPS (2)
  20. Install gearshift cable bracket (2) and torque bolts (3). See Fig 10.
  21. Install gearshift crossover and selector cables (4) to transaxle shift mechanism. Secure to cable bracket with NEW retainer clips.
    Fig 11: Air Cleaner/PDC Bracket
    GC0022004Courtesy of DAIMLERCHRYSLER CORP.
    1 - BRACKET
    2 - BOLT (4)
  22. Install PDC/air cleaner assembly bracket (1). See Fig 11.
    Fig 12: Air Cleaner Assembly
    GC0022003Courtesy of DAIMLERCHRYSLER CORP.
    1 - DUCT
    2 - MASS AIR FLOW SENSOR
    3 - AIR CLEANER ASSEMBLY
    4 - BRACKET
  23. Install PDC into position.
  24. Install air cleaner assembly (3). See Fig 12.
  25. Connect battery negative cable.
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