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Section 42 (2.0L Engine (Service Information)): Installation: Engine

WARNING: This page is about a different car, the 2009 Dodge Caliber. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Removing/Installing Engine Mount Adapter & Engine Mount
GC0098582Courtesy of CHRYSLER LLC
  1. Position engine assembly over vehicle and slowly lower the engine into place.
  2. Continue lowering engine until engine and transaxle are aligned. to mounting locations.
  3. Install engine mount adapter (2) and tighten bolts (3). Install mount through bolt (4) and tighten to 118 N.m (87 ft. lbs.).
    Fig 2: Removing/Installing Engine Lift Chain
    GC0084090Courtesy of CHRYSLER LLC
  4. Remove engine lift chain (1).
  5. Install oil control valve.
    Fig 3: Removing/Installing A/C Compressor
    GC0084091Courtesy of CHRYSLER LLC
  6. Raise vehicle.
  7. Install A/C compressor (1).
    Fig 4: Removing/Installing Exhaust Manifold, Heat Shields, & Oxygen Sensor
    GC0084092Courtesy of CHRYSLER LLC
  8. Install exhaust manifold and heat shields (2). See Engine/Manifolds/MANIFOLD, Exhaust - Installation .
  9. Install oxygen sensor and connect electrical connector (3).
    Fig 5: Crankshaft Position Sensor
    GC0098583Courtesy of CHRYSLER LLC
  10. Install crankshaft position sensor (2) and connect connector.
    Fig 6: Removing/Installing Exhaust Manifold, Heat Shields, & Oxygen Sensor
    GC0084092Courtesy of CHRYSLER LLC
  11. Install manifold to exhaust pipe bolts (1) and tighten bolts.
  12. Install generator.
    Fig 7: Removing/Installing Lower Bell Housing Bolts & Torque Converter Bolts
    GC0084093Courtesy of CHRYSLER LLC
  13. Install lower bell housing bolts (2) and tighten bolts.
  14. Align torque converter and flex plate mark. Install torque converter bolts (1) and tighten.
    Fig 8: Removing/Installing Inspection Cover
    GC0098584Courtesy of CHRYSLER LLC
  15. Install inspection cover (1).
    Fig 9: Identifying Damper Holder 9707
    GC0084094Courtesy of CHRYSLER LLC
  16. Install crankshaft damper.
  17. Install Damper holder 9707 (1).
  18. Apply clean engine oil crankshaft damper bolt threads and between bolt head and washer. Tighten bolt to 210 N.m (155 ft. lbs.).
  19. Install right splash shield.
  20. Install tire.
    Fig 10: Identifying Oil Cooler & Oil Filter
    GC0084095Courtesy of CHRYSLER LLC
  21. Install coolant hose to oil cooler (2).
  22. Install new oil filter (3).
  23. Lower vehicle.
  24. Install upper idler pulley.
    Fig 11: Removing/Installing Coolant Adapter Assembly
    GC0084096Courtesy of CHRYSLER LLC
  25. Install coolant adapter assembly (3).
    Fig 12: Removing/Installing Ground Strap
    GC0098585Courtesy of CHRYSLER LLC
  26. Install Ground strap (1) near right strut tower.
    Fig 13: Removing/Installing Power Steering Line Support Bracket
    GC0098586Courtesy of CHRYSLER LLC
  27. Install power steering line support bracket (1).
  28. Install power steering pump.
  29. Install accessory drive belt.
  30. Connect electrical connectors at block ground, starter, A/C compressor, knock sensor, Oil pressure sensor, generator, Coolant temperature sensor at block, and block heater (if equipped).
    Fig 14: Removing/Installing Intake Bolts - Torque Sequence
    GC0098575Courtesy of CHRYSLER LLC
  31. Install intake manifold. See Engine/Manifolds/MANIFOLD, Intake - Installation .
    Fig 15: Removing/Installing Throttle Body Support & Harness Retainer
    GC0098587Courtesy of CHRYSLER LLC
  32. Install throttle body support bracket (1).
  33. Install harness retainer (2).
  34. Install engine oil level indicator.
    Fig 16: Identifying PCV Hose, Make-Up Air Hose, Fuel Line, Injector Electrical Connectors, & Coil Electrical Connectors
    GC0084097Courtesy of CHRYSLER LLC
  35. Install PCV hose (5) to valve cover.
  36. Install make-up air hose (2).
  37. Connect manifold flow control valve and electronic throttle control electrical connectors.
  38. Install vacuum lines at throttle body and intake manifold.
  39. Install intake air tube to throttle body.
    Fig 17: Identifying PCV Hose, Make-Up Air Hose, Fuel Line, Injector Electrical Connectors, & Coil Electrical Connectors
    GC0084097Courtesy of CHRYSLER LLC
  40. Connect coil electrical connectors (1).
  41. Connect injector electrical connectors (4).
  42. Connect fuel line (3) to rail.
  43. Connect intake and exhaust oil control valve electrical connectors.
    Fig 18: Removing/Installing Upper Radiator Support Bracket
    GC0098588Courtesy of CHRYSLER LLC
  44. Install grill trim panel.
  45. Install upper radiator support bracket (1).
    Fig 19: Removing/Installing Coolant Adapter Assembly
    GC0084096Courtesy of CHRYSLER LLC
  46. Connect coolant temperature sensor (1).
  47. Connect capacitor electrical connector (2).
  48. Install coolant hoses at coolant adapter (3).
    Fig 20: Removing/Installing Coolant Reservoir
    GC0098589Courtesy of CHRYSLER LLC
  49. Install coolant reservoir (3) and connect hose.
    Fig 21: Removing/Installing Battery Tray
    GC0098590Courtesy of CHRYSLER LLC
  50. Install battery tray (1).
    Fig 22: Removing/Installing Battery
    GC0084098Courtesy of CHRYSLER LLC
  51. Install battery (3).
  52. Connect battery cables.
    Fig 23: Removing/Installing Air Cleaner Housing & Clean Air Hose
    GC0084099Courtesy of CHRYSLER LLC
  53. Install air cleaner housing (1) and connect inlet air hose.
  54. Install clean air hose (5).
  55. Fill with coolant.
  56. Fill with oil.
  57. Start engine and check for leaks.
    Fig 24: Removing/Installing Engine Cover - 2.0L
    GC0098591Courtesy of CHRYSLER LLC
  58. Install engine cover (1).
  59. Install hood.
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