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Section 43 (2.4L Engine (Service Information)): Installation: Base

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: LIFT CHAIN
GC0102964Courtesy of CHRYSLER LLC
  1. Position engine over engine compartment and slowly lower into place.
  2. Align engine and transaxle.
  3. Install upper bellhousing bolts and tighten.
    Fig 2: RIGHT ENGINE MOUNT
    GC0102965Courtesy of CHRYSLER LLC
  4. Install mounting bolts (3) at the right mount bolts and tighten bolts to 118 N.m (87 ft. lbs.).
    Fig 3: MODULAR CLUTCH TO FLEX PLATE BOLT
    GC0102966Courtesy of CHRYSLER LLC
  5. Install clutch to flex plate bolts (1).
  6. Install lower bell housing bolts (2) and tighten.
    Fig 4: INSPECTION COVER
    GC0102967Courtesy of CHRYSLER LLC
  7. Install inspection cover (1).
    Fig 5: Crankshaft Position Sensor
    GC0102968Courtesy of CHRYSLER LLC
  8. Connect crankshaft position sensor (2). Connect crankshaft position sensor electrical connector.
    Fig 6: GROUND STRAP
    GC0102969Courtesy of CHRYSLER LLC
  9. Install Ground strap (1).
  10. Raise vehicle.
    Fig 7: Exhaust Pipe Strap
    GC0102970Courtesy of CHRYSLER LLC
  11. Remove strap (2) from exhaust pipe (1).
    Fig 8: CAT AT EXHAUST MANIFOLD
    GC0102918Courtesy of CHRYSLER LLC
  12. Install new manifold to catalytic converter gasket (1) and install catalytic converter to exhaust manifold and tighten.
  13. Connect oxygen sensor electrical connector (3).
  14. Install generator.
    Fig 9: A/C COMPRESSOR
    GC0102971Courtesy of CHRYSLER LLC
  15. Install A/C compressor (1).
    Fig 10: DAMPER REMOVAL
    GC0102972Courtesy of CHRYSLER LLC
  16. Install crankshaft damper.
  17. Apply clean engine oil crankshaft damper bolt threads and between bolt head and washer. Tighten bolt to 210 N.m (155 ft. lbs.).
  18. Install right splash shield.
  19. Install right tire.
    Fig 11: OIL COOLER
    GC0102973Courtesy of CHRYSLER LLC
  20. Install oil cooler if equipped (2). See Engine/Lubrication/COOLER, Oil - Installation .
  21. Connect coolant hoses to oil cooler (2), if equipped.
  22. Install new oil filter (3).
  23. Lower vehicle.
  24. Install upper idler pulley.
    Fig 12: POWER STEERING LINE SUPPORT
    GC0102974Courtesy of CHRYSLER LLC
  25. Install power steering pump.
  26. Install power steering line support bracket at engine mount (1).
    Fig 13: POWER STEERING HOSE SUPPORT-FWD
    GC0102975Courtesy of CHRYSLER LLC
  27. Install power steering hose support (2) at exhaust manifold.
  28. Install accessory drive belt.
    Fig 14: Removing/Installing Intake Bolts In Sequence
    GC0082457Courtesy of CHRYSLER LLC
  29. Connect electrical connectors at block ground, starter, A/C compressor, knock sensor, Oil pressure sensor, generator, Coolant temperature sensor at block, and block heater.
  30. Install intake manifold. See Engine/Manifolds/MANIFOLD, Intake - Installation .
    Fig 15: THROTTLE BODY SUPPORT
    GC0102976Courtesy of CHRYSLER LLC
  31. Install throttle body support bracket (1).
  32. Install engine oil dip stick.
  33. Install vacuum lines at throttle body and intake manifold.
  34. Connect manifold flow control valve and electronic throttle control electrical connectors and fasten harness to intake.
    Fig 16: COIL CONNECTOR
    GC0084062Courtesy of CHRYSLER LLC
  35. Install intake air tube on throttle body.
  36. Install PCV hose (5) to valve cover.
  37. Connect fuel line (3) to fuel rail.
  38. Connect coils (1), injectors (4), oil temperature sensor, cam position sensors.
    Fig 17: RADIATOR HOSE SUPPORT
    GC0102977Courtesy of CHRYSLER LLC
  39. Install upper radiator support bracket (1).
    Fig 18: COOLANT ADAPTER
    GC0102978Courtesy of CHRYSLER LLC
  40. Connect engine coolant temperature sensor (1), and capacitor (2).
  41. Install coolant hoses at coolant adapter (3).
  42. Connect purge hose (4).
    Fig 19: COOLANT RESERVOIR
    GC0102979Courtesy of CHRYSLER LLC
  43. Install coolant reservoir (3) and connect hose.
    Fig 20: BATTERY TRAY
    GC0102980Courtesy of CHRYSLER LLC
  44. Install battery tray (1).
    Fig 21: BATTERY
    GC0102981Courtesy of CHRYSLER LLC
  45. Install hood.
  46. Install battery (3).
  47. Connect battery cables.
    Fig 22: AIR CLEANER HOUSING
    GC0102982Courtesy of CHRYSLER LLC
  48. Install air cleaner housing (1) and connect inlet air hose (5).
    Fig 23: AIR CLEANER INLET
    GC0102983Courtesy of CHRYSLER LLC
  49. Install fresh air inlet (2) and tighten retainers (5).
  50. Fill with coolant. Refer to Cooling - Standard Procedure .
  51. Fill with oil.
    Fig 24: ENGINE COVER
    GC0102984Courtesy of CHRYSLER LLC
  52. Start engine and check for leaks.
  53. Install engine cover (1).
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