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Engine Assembly

WARNING: This page is about a different variant/trim than selected.
Fig 1: Powertrain Dolly & Engine Support Cradle With Posts
GC0121570Courtesy of CHRYSLER LLC
  1. Position the engine/transaxle assembly under the vehicle and slowly lower the vehicle in short length spans. Inspect at each interval for potential engine or transaxle contact to vehicle components. Move the cradle/dolly fixture (2) as necessary to allow for installation clearance.
    Fig 2: RIGHT MOUNT V6
    GC0121572Courtesy of CHRYSLER LLC
  2. Continue lowering the vehicle until the right side engine mount (3) and left side transaxle mount align to their mounting locations. Install the right side engine mount bolts (1) and tighten to 50 N.m (37 ft. lbs.).
    Fig 3: LEFT MOUNT
    GC0121484Courtesy of CHRYSLER LLC
  3. Install the left side transaxle mount bolts (2) and tighten to 98 N.m (72 ft. lbs.).
    Fig 4: Identifying Rear Mount Bracket-To-Transaxle Case Bolts
    GC0121569Courtesy of CHRYSLER LLC
  4. Connect the oil cooler lines to the transaxle. An audible 'click' should be heard. Verify the connection by pulling outward. Refer to Cooling/Transmission - Standard Procedure .
  5. Position the transaxle bracket on the transaxle and install bolts (1). Finger tighten the bolts (1) at this time.
  6. Remove the safety straps from the engine/transaxle assembly. Slowly raise the vehicle and remove the engine dolly and cradle.
    Fig 5: Identifying Transaxle Bracket & Through Bolt
    GC0121568Courtesy of CHRYSLER LLC
  7. Raise and support the vehicle.
  8. Install the fourth transaxle bracket bolt (3) and tighten to 95 N.m (70 ft. lbs.).
  9. Install the transaxle bracket to isolator through bolt (1) and tighten to 75 N.m (55 ft. lbs.).
    Fig 6: TORQUE CONVERTER BOLTS
    GC0121567Courtesy of CHRYSLER LLC
  10. Install the torque converter-to-driveplate bolts (1) and tighten to 88 N.m (65 ft. lbs.).
    Fig 7: DUST SHIELD
    GC0121565Courtesy of CHRYSLER LLC
  11. If equipped with the 62TE transmission, install the torque converter dust shield (2) and bolt (1) tightened to 6 N.m (53 in. lbs.).
    Fig 8: Structural Collar & Bolts
    GC0121566Courtesy of CHRYSLER LLC
  12. If equipped with the 41TE transmission, install the structural collar (3) as follows:
    CAUTION: The collar must be tightened using this service procedure, as damage to transaxle case and/or oil pan may occur.
    NOTE: Make sure that structural collar (3) is flush with the oil pan and the transmission bell housing.
    Fig 9: Rear Maniverter, Fasteners & Gasket
    GC0121564Courtesy of CHRYSLER LLC
    • Position the structural collar (3) on the engine and transaxle.
    • Install and finger tighten all bolts (1) and (2).
    • Pre-tighten the vertical collar bolts (2) to 1.1 N.m (10 in. lbs.).
    • Tighten the horizontal collar bolts (1) to 55 N.m (40 ft. lbs.).
    • Starting from the center and working outward, tighten the vertical collar bolts (2) to 55 N.m (40 ft. lbs.).
  13. Clean the rear maniverter gasket mounting surfaces. See Engine - Standard Procedure .
  14. Install the rear maniverter gasket (3), rear maniverter (2) and the rear maniverter fasteners (1). Tighten the fasteners to 23 N.m (17 ft. lbs.).
    Fig 10: Rear Maniverter Heat Shield
    GC0121563Courtesy of CHRYSLER LLC
  15. Install the rear maniverter heat shield (3). Tighten fasteners (1 and 2) to 12 N.m (106 in. lbs.).
    Fig 11: Downstream & Upstream Oxygen Sensors
    GC0121562Courtesy of CHRYSLER LLC
    1 - ENGINE HARNESS CONNECTOR FOR O2 SENSOR 2/1
    2 - UPPER REAR UPSTREAM O2 SENSOR 2/1
    3 - LOWER REAR DOWNSTREAM O2 SENSOR 2/2
    4 - RIGHT ENGINE SIDE CATALYTIC CONVERTER
    5 - ENGINE HARNESS CONNECTOR FOR O2 SENSOR 2/2
  16. Connect the rear downstream oxygen sensor (3) to the engine wiring harness connector (5).
  17. Connect the rear upstream oxygen sensor (2) to the engine wiring harness connector (1).
    Fig 12: Identifying Intermediate Shaft, Heat Shield & Bolts
    GC0120803Courtesy of CHRYSLER LLC
  18. Install the intermediate shaft (4).
  19. Install the intermediate shaft bolts (1) and (5). Tighten bolt (1) to 38 N.m (28 ft. lb.) and bolts (5) to 23 N.m (17 ft. lb.).
  20. Install the heat shield (3) and heat shield bolts (2).
    Fig 13: Crossunder Pipe
    GC0121556Courtesy of CHRYSLER LLC
  21. Install the crossunder pipe (3) to the rear maniverter with pipe fasteners (1) and (2). Hand tighten fasteners.
    Fig 14: 2.7L Extension Pipe
    GC0121573Courtesy of CHRYSLER LLC
  22. Install the exhaust extension pipe (2) to the cross under pipe with pipe fasteners (1). Hand tighten fasteners.
    Fig 15: Identifying Rear Mount Bracket-To-Transaxle Case Bolts
    GC0121569Courtesy of CHRYSLER LLC
  23. Lower the vehicle.
  24. Tighten the three previously installed rear engine mount bracket bolts (1) to 95 N.m (70 ft. lbs.).
    Fig 16: 2.7L LOWER EGR TUBE
    GC0121561Courtesy of CHRYSLER LLC
  25. Install the lower EGR tube (2). Refer to Emissions Control/Exhaust Gas Recirculation/TUBE, Exhaust Gas Recirculation (EGR) - Installation .
    Fig 17: Front Exhaust Maniverter & Gasket
    GC0121560Courtesy of CHRYSLER LLC
  26. Clean the front maniverter gasket mounting surfaces. See Engine - Standard Procedure .
  27. Install a new gasket (3), front maniverter (2) and the front exhaust maniverter attaching bolts (1). Tighten the bolts to 23 N.m (17 ft. lbs.).
    Fig 18: FRONT MANIVERTER HEAT SHIELD
    GC0121559Courtesy of CHRYSLER LLC
  28. Install the upper maniverter heat shield (2) and the heat shield fasteners (1). Tighten fasteners to 12 N.m (106 in. lbs.).
    Fig 19: COOLANT RECOVERY CONTAINER - PRESSURE SYSTEM
    GC0120878Courtesy of CHRYSLER LLC
  29. Connect the coolant recovery container hose (3) from the radiator to the coolant recovery container (4).
  30. Install the coolant recovery container (4) with two fasteners (1). Tighten fasteners to 10 N.m (89 in. lbs.).
  31. Connect the return hose (2) to the coolant recovery container (4).
    Fig 20: Identifying Upper Radiator Hose, Heater Hose, Power Steering Reservoir, Connectors & Screw
    GC0121558Courtesy of CHRYSLER LLC
  32. Install the heater hose (3) to the coolant outlet connector (4).
  33. Install the upper radiator hose (5) to the coolant outlet connector (4).
  34. Install the power steering reservoir (2) to the strut tower bracket with the mounting screw (1). Tighten the mounting screw to 12 N.m (106 in. lbs.).
    Fig 21: GENERATOR
    GC0120978Courtesy of CHRYSLER LLC
  35. Raise and support the vehicle.
  36. Install the generator with two upper mounting bolts. Hand tighten bolts.
  37. Install the lower generator mounting bolt and tighten to 27 N.m (20 ft. lbs.).
  38. Tighten the two upper generator mounting bolts to 27 N.m (20 ft. lbs.).
    Fig 22: Removing/Installing A/C Compressor
    GC0121574Courtesy of CHRYSLER LLC
  39. Install the A/C compressor (1) to the engine with three bolts (2). Tighten the bolts to 25 N.m (18 ft. lbs.).
    Fig 23: Identifying Heater Return Hose & Lower Radiator Hose
    GC0121557Courtesy of CHRYSLER LLC
  40. Connect the heater return hose (1) to the pipe connection at right front frame rail area.
  41. Connect the lower radiator hose (2).
    Fig 24: 2.7L MANIVERTER TO CROSS UNDER PIPE
    GC0121575Courtesy of CHRYSLER LLC
  42. Install the front maniverter-to-cross under pipe fasteners (1) and (2). Tighten to 27 N.m (20 ft. lb.).
  43. Tighten the previously installed rear maniverter-to-cross under pipe fasteners to 29 N.m (21 ft. lb.).
  44. Tighten the previously installed exhaust extension pipe to the cross under pipe fasteners to 27 N.m (20 ft. lb.).
    Fig 25: REAR PUMP MOUNTING BRACKET BOLTS - 2.7L
    GC0121555Courtesy of CHRYSLER LLC
  45. Install the power steering pump and bracket assembly (1) with two pump mounting bracket bolts (2) behind the pump on the back of the engine. Do not tighten the bolts at this time.
    Fig 26: FRONT PUMP MOUNTING BRACKET BOLTS - 2.7L
    GC0121554Courtesy of CHRYSLER LLC
  46. Install the pump mounting bracket bolt (1) near the pump pulley.
  47. Tighten all three pump mounting bracket bolts to 30 N.m (22 ft. lbs.).
    Fig 27: STRETCH TO FIT POWER STEERING BELT REMOVAL
    GC0121553Courtesy of CHRYSLER LLC
    1 - POWER STEERING PULLEY
    2 - STRETCH TO FIT POWER STEERING BELT
  48. Install the power steering belt (2). Refer to Cooling/Accessory Drive/BELT, Serpentine - Installation .
    Fig 28: Accessory Drive Belt System - 2.7L
    GC0121552Courtesy of CHRYSLER LLC
    1 - GENERATOR
    2 - IDLER/TENSIONER
  49. Install the accessory drive belt (2). Refer to Cooling/Accessory Drive/BELT, Serpentine - Installation .
    Fig 29: FORE/AFT CROSSMEMBER 2
    GC0121551Courtesy of CHRYSLER LLC
  50. Install the fore/aft cross-member (4). Refer to Frame and Bumpers/Frame/CROSSMEMBER - Installation .
    Fig 30: FRONT SPLASH SHIELDS
    GC0121576Courtesy of CHRYSLER LLC
  51. Install the left and right splash shields (2). Refer to Body/Exterior/SHIELD, Splash - Installation .
    Fig 31: HUB NUT
    GC0121549Courtesy of CHRYSLER LLC
  52. Install both axle shafts (2). Refer to Differential and Driveline/Half Shaft - Installation .
    Fig 32: LOWER FASCIA
    GC0121548Courtesy of CHRYSLER LLC
  53. Install the closeout panel (1) onto the fascia (3). Refer to Frame and Bumpers/Bumpers/FASCIA, Front Lower - Installation .
    Fig 33: LOWER SPLASH SHIELD
    GC0121547Courtesy of CHRYSLER LLC
  54. Install the left and right lower frame splash shields (2).
    Fig 34: TIRE AND WHEEL MOUNTING
    GC0082325Courtesy of CHRYSLER LLC
  55. Install the front tire and wheel assemblies. Refer to Tires and Wheels - Installation .
    Fig 35: Belly Pan
    GC0121546Courtesy of CHRYSLER LLC
  56. Ensure that the oil pan drain plug is tight and install a new oil filter. See Engine/Lubrication/FILTER, Engine Oil - Installation .
  57. Install the belly pan (2), if equipped.
    Fig 36: Discharge Line To Jumper
    GC0121545Courtesy of CHRYSLER LLC
  58. Lower the vehicle.
  59. Remove the tape or plugs from the A/C discharge line (2) and jumper line (4) fittings.
  60. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  61. Connect the A/C discharge line (2) to the jumper line (4).
  62. Install the nut (3) that secures the A/C discharge line to the jumper line. Tighten the nut to 18 N.m (13 ft. lbs.).
  63. Connect the wire harness connector (1) to the A/C pressure transducer (6).
    Fig 37: A/C Compressor-Refrigerant Lines
    GC0121577Courtesy of CHRYSLER LLC
  64. Remove the tape or plugs from the compressor port and the refrigerant line fitting.
  65. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the suction line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  66. Connect the A/C suction line (6) to the A/C compressor (3).
  67. Install the nut (4) that secures the A/C suction line to the A/C compressor. Tighten the nut to 20 N.m (15 ft. lbs.).
  68. Connect the engine wire harness (1) to the A/C compressor connector (2).
    Fig 38: Identifying Oil Dipstick Tube & Bolt
    GC0121544Courtesy of CHRYSLER LLC
  69. Install the engine oil dipstick and tube (2). Tighten bolt to 20 N.m (15 ft. lbs.).
    Fig 39: GENERATOR BATTERY CABLE
    GC0120977Courtesy of CHRYSLER LLC
  70. Connect the generator B+ terminal and field connectors.
    Fig 40: Locating Cooling Fan Module, Screws, Retainers & Connectors
    GC0121543Courtesy of CHRYSLER LLC
  71. Install the cooling fan module (2) to the radiator and engage the two upper retainers.
  72. Install five screws (1) retaining the wire harness to the upper core support.
  73. Connect the fan motor electrical connectors (4).
  74. Secure three wire harness retainers (3) and the wire harness connector (5) to the cooling fan module (2).
    Fig 41: Downstream & Upstream Oxygen Sensors
    GC0121542Courtesy of CHRYSLER LLC
    1 - ENGINE HARNESS CONNECTOR FOR O2 SENSOR 1/1
    2 - ENGINE HARNESS CONNECTOR FOR O2 SENSOR 1/2
    3 - LOWER FRONT DOWNSTREAM O2 SENSOR 1/2
    4 - LEFT ENGINE SIDE CATALYTIC CONVERTER
    5 - UPPER FRONT UPSTREAM O2 SENSOR 1/1
  75. Connect the front downstream oxygen sensor (3) to the engine wiring harness connector (2).
  76. Connect the front upstream oxygen sensor (5) to the engine wiring harness connector (1).
    Fig 42: SHIFT CABLE FROM MANUAL LEVER
    GC0121541Courtesy of CHRYSLER LLC
  77. Connect the gearshift cable (1) to the manual valve lever (2).
    Fig 43: Locating Fuel Supply Hose & Fuel Rail
    GC0121540Courtesy of CHRYSLER LLC
  78. Connect the fuel supply hose (2) to the fuel rail (1). Refer to Fuel System/Fuel Delivery/FITTING, Quick Connect - Standard Procedure .
    Fig 44: Locating Upper Intake Manifold
    GC0121539Courtesy of CHRYSLER LLC
  79. Install the upper intake manifold (1). See Engine/Manifolds/MANIFOLD, Intake - Installation .
    Fig 45: Identifying Harness Connectors & Nuts
    GC0121538Courtesy of CHRYSLER LLC
  80. Connect engine harness to main harness connectors (5) and (6).
  81. Connect engine harness connector C2 (4) and transmission harness connector C4 (3) to the PCM.
  82. Install the black ground cable to the remote negative battery post. Tighten the nut (2) to 16.5 N.m (145 in. lbs.).
  83. Install the red starter cable to the remote positive battery post. Tighten the nut (1) to 16.5 N.m (145 in. lbs.).
    Fig 46: AIR BOX COVER
    GC0121537Courtesy of CHRYSLER LLC
    1 - Inlet Hose
    2 - IAT sensor
    3 - Fresh Air Hose
  84. Install the throttle body air inlet hose and air cleaner body assembly. See Engine/Air Intake System/BODY, Air Cleaner - Installation .
  85. Evacuate and recharge the Air Conditioning system. Refer to Heating and Air Conditioning/Plumbing - Standard Procedure .
  86. Fill the engine crankcase with the proper oil to the correct level. See Engine/Lubrication/OIL - Standard Procedure .
  87. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lb.).
  88. Fill the cooling system. Refer to Cooling - Standard Procedure .
  89. Start the engine and run until operating temperature is reached.
    NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components. Refer to DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .
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