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Engine Assembly

WARNING: This page is about a different car, the 2013 Dodge Avenger and 2013 Chrysler 200. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:

If the original engine has experienced a catastrophic failure or an individual failure with the piston, cylinder bore, engine block, valve or valve seat, the intake manifold MUST be replaced with a new manifold.

Fig 1: Lift Chain
GC0121400Courtesy of CHRYSLER GROUP, LLC
  1. Connect engine lift chain (1) to engine.
  2. Slowly lower engine assembly in to position.
    Fig 2: Right Engine Mount & Fasteners
    GC0121401Courtesy of CHRYSLER GROUP, LLC
  3. Position right mount bracket (2) and install bolts (3).
  4. Install mounting bolts at the right engine mount bolts and tighten bolts to 118 N.m (87 ft. lbs.).
  5. Install through bolt (4) and tighten to 118 N.m (87 ft. lbs.).
    Fig 3: A/C Compressor & Bracket
    GC0121402Courtesy of CHRYSLER GROUP, LLC
  6. Install A/C compressor mounting bracket (2).
  7. Install A/C compressor (1) and connect lines.
  8. Install exhaust manifold and upper lower heat shields (Refer to INSTALLATION ).
  9. Install oxygen sensor and connect electrical connector.
    Fig 4: Ground Strap
    GC0121403Courtesy of CHRYSLER GROUP, LLC
  10. Install Ground strap (1) near right strut tower.
  11. Raise vehicle.
    Fig 5: Crankshaft Position Sensor & Bolt
    GC0121404Courtesy of CHRYSLER GROUP, LLC
  12. Install crankshaft position sensor (CKP) (2).
  13. Connect CKP electrical connector (2).
    Fig 6: Exhaust Manifold Bolts, Heat Shield & Oxygen Sensor Connector
    GC0121405Courtesy of CHRYSLER GROUP, LLC
  14. Install manifold to exhaust pipe bolts (1) and tighten bolts.
  15. Install generator.
    Fig 7: Removing/Installing Modular Clutch-To-Drive Plate Bolts
    GC0121406Courtesy of CHRYSLER GROUP, LLC
  16. Install lower bell housing bolts (2) and tighten.
  17. Align torque converter and flex plate mark. Install torque converter bolts (1) and tighten.
    Fig 8: Inspection Cover
    GC0121407Courtesy of CHRYSLER GROUP, LLC
  18. Install inspection cover (1).
    Fig 9: Oil Filter
    GC0121408Courtesy of CHRYSLER GROUP, LLC
  19. Install new oil filter (1).
  20. Lower vehicle.
  21. Install upper idler pulley.
  22. Install power steering pump.
    Fig 10: Power Steering Line Support
    GC0121409Courtesy of CHRYSLER GROUP, LLC
  23. Install power steering line support bracket (1).
  24. Install power steering pump.
  25. Install accessory drive belt.
  26. Connect electrical connectors at block ground, starter, A/C compressor, knock sensor, oil pressure sensor, generator, coolant temperature sensor at block, and block heater.
    Fig 11: Intake Bolt Removal/Tightening Sequence
    GC0121410Courtesy of CHRYSLER GROUP, LLC
  27. Install intake manifold and tighten bolts to 24 N.m (18 ft. lbs.) as shown in illustration.
    Fig 12: Throttle Body Support Bracket & Wiring Harness Retainer
    GC0121411Courtesy of CHRYSLER GROUP, LLC
  28. Install throttle body support bracket (1).
  29. Connect manifold flow control valve and electronic throttle control electrical connectors.
  30. Insert wiring harness retainer into intake manifold (2).
  31. Install engine oil dip stick.
    Fig 13: Ignition Coils, Air Hose, Fuel Line, Injectors & PCV Hose
    GC0121412Courtesy of CHRYSLER GROUP, LLC
  32. Install PCV hose (5).
  33. Install vacuum lines at throttle body and intake manifold.
  34. Install intake air tube on throttle body.
  35. Connect engine harness electrical connectors.
    Fig 14: Coolant Temperature Sensor Connector, Capacitor Connector & Coolant Adapter
    GC0121413Courtesy of CHRYSLER GROUP, LLC
  36. Install coolant hoses at coolant adapter (3).
    Fig 15: Coolant Reservoir, Power Steering Reservoir & Windshield Washer Bottle
    GC0121414Courtesy of CHRYSLER GROUP, LLC
  37. Install coolant reservoir (1) and connect hose.
    Fig 16: Ignition Coils, Air Hose, Fuel Line, Injectors & PCV Hose
    GC0121412Courtesy of CHRYSLER GROUP, LLC
  38. Connect fuel line to fuel rail (3).
    Fig 17: Battery Cables
    GC0121415Courtesy of CHRYSLER GROUP, LLC
  39. Connect negative battery cable (1).
    Fig 18: Air Cleaner Housing Assembly
    GC0121416Courtesy of CHRYSLER GROUP, LLC
  40. Install air cleaner housing (1) and connect inlet air hose (Refer to INSTALLATION ).
  41. Fill with coolant.
  42. Fill with oil.
    CAUTION:

    Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage.

  43. Evacuate the refrigerant system (refer to REFRIGERANT SYSTEM EVACUATE ).
  44. Charge the refrigerant system (refer to REFRIGERANT SYSTEM CHARGE ).
    Fig 19: Engine Cover - 2.4L
    GC0121417Courtesy of CHRYSLER GROUP, LLC
  45. Start engine and check for leaks.
  46. Install engine cover (1).
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