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Home >> Chrysler >> 2009 >> 300 Signature Series >> Repair and Diagnosis >> External Pages >> Different car >> Section 208 (2.4L Engine (Service Information)) >> Installation >> Engine Assembly

Engine Assembly

WARNING: This page is about a different car, the 2007 Chrysler PT Cruiser. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Positioning Engine Cradle Support Post
GC0021170Courtesy of CHRYSLER LLC
  1. Position engine and transmission assembly under vehicle and slowly lower the vehicle over the engine/transaxle assembly.
    Fig 2: Identifying Right Mount Through Bolt
    GC0021168Courtesy of CHRYSLER LLC
    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: Identifying Left Mount & Bolt
    GC0021169Courtesy of CHRYSLER LLC
  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 CHRYSLER LLC
  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: Identifying Pressure Hose Connection To Pump
    GC0042759Courtesy of CHRYSLER LLC
  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 CHRYSLER LLC
  9. Install lower engine torque strut (5). Refer to 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 CHRYSLER LLC
  12. Install structural collar (4). See INSTALLATION .
    Fig 8: Turbocharger Brackets & Heat Shields
    GC0019350Courtesy of CHRYSLER LLC
  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 CHRYSLER LLC
  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 CHRYSLER LLC
  15. Turbocharger equipped vehicles:   Connect both power steering hoses (5) to steering gear (1). See Fig 10.
    Fig 11: Converter To Exhaust Manifold Connection - 2.4L
    GC0021165Courtesy of CHRYSLER LLC
  16. Connect exhaust system (2) to manifold.
  17. Connect the downstream oxygen sensor.
    Fig 12: Charge Air Cooler Hoses
    GC0019344Courtesy of CHRYSLER LLC
  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 .
    Fig 13: Identifying Splash Shield
    GC0042765Courtesy of CHRYSLER LLC
  22. Install axle shafts. Refer to 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: Identifying Clutch Hydraulic Line To Slave Cylinder
    GC0020072Courtesy of CHRYSLER LLC
  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: Locating A/C Lines
    GC0042752Courtesy of CHRYSLER LLC
  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 & Center Brace
    GC0019362Courtesy of CHRYSLER LLC
  32. Install upper radiator closure panel (1) and center brace (2). Refer to INSTALLATION . . See Fig 16.
    Fig 17: Removing/Installing Grille
    GC0042757Courtesy of CHRYSLER LLC
  33. Install grille (2) and tighten grill retaining fasteners (1). Refer to 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 CHRYSLER LLC
  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 INSTALLATION .
  43. Connect cables to battery.
    Fig 19: Identifying Air Cleaner
    GC0042753Courtesy of CHRYSLER LLC
  44. Install air cleaner housing assembly and connect clean air hose. Refer to 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 COOLING .
  48. Evacuate and recharge A/C system. Refer to HEATING & AIR CONDITIONING - SERVICE INFORMATION .
  49. Start engine and run until operating temperature is reached. Check for leaks.
  50. Perform torque strut adjustment procedure. Refer to ADJUSTMENTS .
  51. Adjust transmission linkage, if necessary.
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