2.4L Engine Removal?

The details and procedure to replace 2.4L Engine.

Please Note that this Procedure Covers all U.S. and Canadian models of the Chrysler/Dodge Avenger, Chrysler Sebring Coupe and Dodge Stratus/ Stratus Coupe models for Year 1999 to 2005.

The complete procedure with help Diagrams to remove/install Engine is as follows:---

1. Properly relieve the fuel system pressure.
2. Drain the engine oil.
3. Drain the cooling system.
4. Recover the A/C refrigerant.
5. Remove or disconnect the following:
   
   
   Hood

   Negative battery cable

   Strut tower bar

   Air cleaner assembly

   Radiator and recovery tank

   Front exhaust pipe

   Accelerator cable connection

   Purge hose connection

   Brake booster vacuum hose connection

   Ignition coil connector

   Injector connectors

   Manifold differential pressure sensor connector

   Throttle Position Sensor (TP) connection

   Heated Oxygen Sensor (HO ₂ S) connection

   Capacitor connection

   Engine Coolant Temperature (ECT) connector

   Camshaft Position (CMP) sensor connector

   Knock Sensor (KS) connector

   Engine coolant temperature gauge unit connector

   Idle Air Control (IAC) motor connector

   Evaporative emission purge solenoid valve

   Exhaust Gas Recirculation (EGR) solenoid valve connector

   High pressure and fuel return fuel hoses

   Pressure hose connection

   Oil dipstick and tube

   Pressure hose connection

   Heater hose

   Alternator connector

   Oil pressure switch connector

   Drive belts

   Crankshaft Position (CKP) sensor connector

   Power steering pressure switch connector
6. Unbolt the power steering pump and bracket, and place aside, as an assembly with the hose attached.
   
   WARNING

   Do NOT disconnect the A/C compressor refrigerant lines!
   
   
   A/C compressor connector. Unbolt and place the A/C compressor aside with the lines attached.
7. Remove the transaxle. Do NOT remove the flywheel assembly bolt shown in the accompanying figure. Removal of this bolt will throw the flywheel out of balance and damage it. 
   
   
   

   Fig. Do not remove the flywheel bolt shown, or you will damage the flywheel
8. Remove the engine mount bracket, as follows:
   1. Support the engine with a suitable jack.
   2. Remove the special tools that were attached during transaxle removal
   3. Hold the engine assembly with a chain block or similar tool.
   4. Place a jack against the oil pan (with a block of wood in between), the jack up the engine so that the weight of the engine is no longer on the engine mount, then remove the engine mount bracket.
9. Remove the engine mount stopper.
10. Make sure that all cables, hoses and electrical connections are disconnected, slowly raise the engine up and out of the engine compartment.

To install:

1. Install or connect the following: 
   
   
   Engine assembly

   Engine mount stopper and torque the bolts to 60 ft. lbs. (81 Nm). Clamp the mount stopper so that the arrow points in the direction shown in the accompanying figure. 
   
   

   

   Fig. Correct installation of the engine mount stopper-2.4L engine

   Engine mount stopper and torque the bolts to 64 ft. lbs. (86 Nm). Remove the engine lifting device

   Transaxle

   A/C compressor and connector

   Power steering pump and bracket

   Power steering pressure switch connector

   CKP sensor connector

   Drive belts

   Oil pressure switch connector

   Alternator connector

   Heater hose

   Pressure hose

   Oil dipstick tube and dipstick

   Pressure hose connector

   Fuel return hose

   High pressure fuel hose. Apply a small quantity of oil to the hose O-ring and then installing using a twisting motion. During installation make sure that the O-ring does not get twisted or clamped and that no engine oil enters fuel rail

   EGR solenoid valve connector

   EVAP purge solenoid valve

   IAC motor connector

   ECT gauge unit connector

   KS connector

   CMP sensor connector

   ECT sensor connector

   Capacitor connector

   HO ₂ S connector

   TP sensor connector

   Manifold differential pressure sensor connector

   Injector connector

   Ignition coil connector

   Vacuum hose connection

   Brake booster vacuum hose

   Purge hose

   Accelerator cable

   Front exhaust pipe

   Radiator reservoir tank and radiator

   Air cleaner

   Strut tower bar

   Negative battery cable

   Hood and adjust as needed
2. Fill the engine with clean oil and replace the filter.
3. Fill the cooling system to the proper level.
4. Recharge the A/C system with the proper refrigerant.
5. Start the vehicle, check for leaks and repair if necessary.

ALSO READ THIS ADDITIONAL HELP:---

1. Remove or disconnect the following: 
   
   
   Negative battery cable

   Throttle body air inlet hose

   Air cleaner assembly

   Upper radiator crossmember

   Upper and lower radiator hoses

   Transmission cooler lines

   A/C lines at the condenser

   Radiator, fan module and A/C condenser

   Transmission electrical harness connectors

   Transmission shift cable

   Engine electrical harness from the Powertrain Control Module (PCM) and bulkhead

   Both front wheels and splash shields

   Both halfshafts

   Drive belts

   Power steering pump from the bracket and move it aside

   Heater return hose from the right front frame rail

   A/C compressor electrical connectors

   Exhaust pipe from the manifold

   Through bolts from the front and rear engine mounts 
   
   

   

   Fig. Exploded view of the right side engine mount-all engines

   
   
   

   

   Fig. Exploded view of the rear engine mounting torque bracket-2.4L engines

   Rear mount bracket from the transmission

   Structural cover and torque reaction bracket 
   
   

   

   Fig. Exploded view of the front engine mounting torque bracket-2.4L engines

   Torque converter bolts after matchmarking them

   Positive battery cable from the battery and the Power Distribution Center (PDC)

   Ground cable from the left side transmission mount bracket

   Throttle and speed control cables

   Coolant overflow hose

   Heater hose from the thermostat housing

   Engine ground straps

   Brake booster and vacuum purge hoses

   Fuel lines from the rail

   Intake manifold

   Alternator

   A/C suction line from the compressor and place an engine dolly and cradle in position
2. Loosen the cradle engine mounts and lower the engine/transmission assembly onto the dolly.
3. Remove the vertical engine mount bolts
4. Slowly raise the vehicle and make certain that the cradle is positioned properly.
5. Secure the engine/transmission assembly to the cradle and remove the assembly. 

To install:

1. Position the engine/transmission assembly under the vehicle and slowly lower the vehicle into position.
2. Continue to the lower the vehicle until the right side engine mount and left side transaxle mount are properly aligned. 
   
   
   

   Fig. Exploded view of the right side engine mount-all engines
   
   
   
   

   Fig. Exploded view of the rear engine mounting torque bracket-2.4L engines
3. Install or connect the following: 
   
   
   Mounting bolts and torque them to 45 ft. lbs. (61 Nm).

   Raise the vehicle and remove the cradle

   A/C compressor and suction line

   Alternator

   Intake manifold and torque the bolts to 105 inch lbs. (12 Nm)

   Alternator electrical connectors

   Fuel line to the rail

   Brake booster and vacuum purge hoses

   Engine ground straps

   Heater hose to the thermostat housing

   Coolant overflow hose

   Throttle and speed control cables

   Ground cable to the left side transmission mount bracket

   Positive battery cable to the PDC

   Torque converter bolts

   Structural cover and the torque reaction bracket 
   
   

   

   Fig. Exploded view of the front engine mounting torque bracket-2.4L engines

   Rear mount bracket to the transmission

   Front and rear engine mount through bolts. Torque the bolts to 45 ft. lbs. (61 Nm)

   Exhaust pipe to the manifold and torque the bolts to 21 ft. lbs. (28 Nm)

   A/C compressor electrical connectors

   Heater return hose to the right front frame rail

   Power steering pump to the bracket

   Drive belts

   Both halfshafts

   Splash shields and front wheels

   Engine electrical harness to the PCM and the bulkhead connectors

   Transmission shift cable

   Transmission electrical connectors

   Radiator, fan module and A/C condenser

   A/C lines to the condenser

   Transmission cooler lines

   Upper and lower radiator hoses

   Upper radiator crossmember

   Air cleaner assembly

   Throttle body air inlet hose

   Negative battery cable
4. Fill the engine with clean oil.
5. Fill the cooling system to the proper level.
6. Recharge the A/C system.
7. Start the vehicle, check for leaks and repair if necessary.

These details will help.

Thanks.           

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html