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2.4L Turbo

  1. Using a lint free towel, wipe clean the open power steering pressure hose end and power steering pump pressure port. Replace any used O-rings with new. Lubricate the O-ring with clean power steering fluid.
  2. Install the power steering pump with pulley and reservoir into its mounting area.
    Fig 1: Pump Mounting - 2.4L Turbo
    GC0019562Courtesy of DAIMLERCHRYSLER CORP.
  3. Place the pump in mounting position with the stamped steel support bracket behind it. Install the three pump mounting bolts through bracket and pump, into threaded engine cover. DO NOT TIGHTEN BOLTS AT THIS TIME.
    Fig 2: Bracket Mounting To Engine - 2.4L Turbo
    GC0019563Courtesy of DAIMLERCHRYSLER CORP.
  4. Install the two bolts fastening the support bracket to the engine block. Tighten the two bolts to 54 N.m (40 ft. lbs.).
    Fig 3: Pump Mounting - 2.4L Turbo
    GC0019562Courtesy of DAIMLERCHRYSLER CORP.
  5. Tighten the three pump mounting bolts previously installed to 28 N.m (250 in. lbs.).
    Fig 4: Hoses At Pump And Engine - 2.4L Turbo
    GC0021712Courtesy of DAIMLERCHRYSLER CORP.
    1 - RESERVOIR (MOUNTED TO PUMP)
    2 - PRESSURE HOSE (SERVICED WITH RETURN HOSE)
    3 - RETURN HOSE (SERVICED WITH PRESSURE HOSE)
    4 - RETURN HOSE (COOLING MODULE TO RESERVOIR)
    5 - TUBE NUT
    6 - POWER STEERING PUMP
  6. Insert the pressure hose (2) end into the pump (6) pressure fitting. Screw the pressure hose tube nut (5) into the pump pressure fitting. Tighten the tube nut to 31 N.m (23 ft. lbs.).
  7. Install the fluid return hose (3) onto the power steering fluid reservoir (1) return fitting. Expand the hose clamp and slide it over the hose and pump return fitting. Secure the clamp once it is past the bead formed into the fluid reservoir fitting.
    Fig 5: Fan Mounting To Cooling Module - 2.4L Turbo
    GC0021715Courtesy of DAIMLERCHRYSLER CORP.
    1 - RADIATOR FAN FASTENERS
    2 - CHARGE AIR COOLER FASTENERS
    3 - RADIATOR FAN CONNECTOR
    4 - CHARGE AIR COOLER
  8. Position the radiator fan and install the two upper and two side mounting screws (1). DO NOT TIGHTEN SCREWS AT THIS TIME.
  9. Position cooling module back into its lower mounts.
    Fig 6: Radiator Inlet Neck - 2.4L Turbo
    GC0021714Courtesy of DAIMLERCHRYSLER CORP.
    1 - FASTENERS
    2 - RADIATOR INLET NECK
  10. Clean and inspect or replace the upper radiator hose inlet neck (2) O-ring, then install the inlet neck to the radiator. Install the two mounting screws.
    Fig 7: Radiator Closure Panel
    GC0021707Courtesy of DAIMLERCHRYSLER CORP.
    1 - FASTENERS
  11. Install the radiator closure panel and fasten it in place (1).
    Fig 8: Temperature Sensor Mounting
    GC0021716Courtesy of DAIMLERCHRYSLER CORP.
    1 - AMBIENT TEMP SENSOR
    2 - AMBIENT TEMP SENSOR
  12. Install the ambient temperature sensors (1, 2) on the radiator closure panel.
  13. Install the hood-opening weather-strip across the radiator closure panel.
    Fig 9: Grille Attachment
    GC0021705Courtesy of DAIMLERCHRYSLER CORP.
    1 - GRILLE
    2 - RETAINER
  14. Install the grille on the front of the vehicle. (Refer to BODY/EXTERIOR/GRILLE - INSTALLATION) .
  15. Raise and support the vehicle.
  16. Install the accessory drive belt. (Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION) .
    Fig 10: DRIVE BELT SPLASH SHIELD
    GC0042967Courtesy of DAIMLERCHRYSLER CORP.
  17. Position the drive-belt splash shield (3) and install the fasteners (4) securing it to the body (2).
  18. Install the fastener (5) securing the drive belt splash shield (3) to the front suspension crossmember (6).
  19. If previously removed, install the fasteners securing the front fascia (1) to the body lower reinforcement.
    Fig 11: SPLASH SHIELD TO SPLASH SHIELD
    GC0042966Courtesy of DAIMLERCHRYSLER CORP.
  20. Install the one fastener (2) securing the wheel house splash shield (1) to the drive belt splash shield (3).
    Fig 12: Tire And Wheel Mounting Method
    GC0041085Courtesy of DAIMLERCHRYSLER CORP.
  21. Install the tire and wheel assembly (1) (Refer to TIRES/WHEELS - INSTALLATION) . Install and tighten wheel mounting nuts (3) to 135 N.m (100 ft. lbs.).
    Fig 13: Fan Mounting To Cooling Module - 2.4L Turbo
    GC0021715Courtesy of DAIMLERCHRYSLER CORP.
    1 - RADIATOR FAN FASTENERS
    2 - CHARGE AIR COOLER FASTENERS
    3 - RADIATOR FAN CONNECTOR
    4 - CHARGE AIR COOLER
  22. Install the two remaining lower fan mounting screws (1). Tighten the screws to 6 N.m (55 in. lbs.).
    Fig 14: Radiator Fan Connector - 2.4L Turbo
    GC0021713Courtesy of DAIMLERCHRYSLER CORP.
    1 - RADIATOR FAN CONNECTOR
    2 - RADIATOR DRAINCOCK
  23. Connect the radiator fan wiring connector (1).
  24. Lower the vehicle.
    Fig 15: Fan Mounting To Cooling Module - 2.4L Turbo
    GC0021715Courtesy of DAIMLERCHRYSLER CORP.
    1 - RADIATOR FAN FASTENERS
    2 - CHARGE AIR COOLER FASTENERS
    3 - RADIATOR FAN CONNECTOR
    4 - CHARGE AIR COOLER
  25. Tighten the two upper and two side radiator fan mounting screws to 6 N.m (55 in. lbs.).
  26. Fill the cooling system (Refer to COOLING - STANDARD PROCEDURE - FILLING COOLING SYSTEM) .
  27. Perform the POWER STEERING PUMP INITIAL OPERATION procedure to properly fill and bleed power steering system. (Refer to STEERING/PUMP - STANDARD PROCEDURE) .
  28. Check for leaks.
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