Sunday, April 22, 2012

Replace 2.0L And 2.5L Engines?

How to remove and install Engine.
The procedure shows details and diagrams and gives complete information for replace 2.0L engine and 2.5L 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 Engine removal is as follows:---

  1. NOTE
    The transaxle must be removed before removing the engine. They will not come out as a unit.
  2. Drain the engine coolant.
  3. Drain the engine oil
  4. Drain the transmission oil.
  5. Properly relieve the fuel system pressure.
  6. Remove or disconnect the following:
    All wires and connectors should be labeled at the time of engine removal. This will save time during assembly.

    Do not disconnect the hoses or allow the pump to hang by the hoses.

    Do not loosen or remove the A/C hoses or discharge the system.

    Negative battery cable
    Engine under cover
    Transaxle assembly
    Radiator by disconnecting the hoses at the engine
    Accelerator cable and bracket
    Heater hoses
    Brake booster vacuum hose at the engine
    Vacuum hoses running to the bulkhead
    High pressure fuel line and discard the O-ring
    Fuel return hose from the fuel supply rail
    Electrical connectors from the engine components

    Accessory drive belts
    Power steering pump move aside

    Power steering pump bracket
    A/C compressor and move aside

    Exhaust system joint bolts just below the manifold and discard the gasket and nuts
  7. Install the engine hoist equipment and make certain the attaching points on the engine are secure. Draw tension on the hoist just enough to support the engine's weight but no more. Do not disturb the placement of the vehicle on the stands. 
    Immediately place it on an engine stand or support it with wooden blocks. Do not allow it to rest on the oil pan or lie on its side. Do not leave the engine hanging from the hoist.

    Rear (bulkhead side) roll stopper through-bolt
    Front engine roll stopper through-bolt
    Upper (right-side) engine mount-to-engine nuts/bolts, through-bolt and mount assembly
    Support bracket below the mount

    Fig. Exploded view of the right-side engine mount-2.0L engine

    Fig. Exploded view of the right-side engine mount-2.5L engine
To install:
  1. Installation is the reverse of the removal procedure. Please note the following important steps:
    1. Connect the exhaust system to the manifold, using a new gasket. Torque the bolts to 33 ft. lbs. (44 Nm).
  2. Torque the engine mount nuts and bolts as follows:
    1. Right-side mount-to-engine nut and bolt: 63 ft. lbs. (86 Nm).
    2. Right-side mount through-bolt: 71-85 ft. lbs. (98-118 Nm).
    3. Rear roll stopper through-bolt: 32 ft. lbs. (44 Nm).
    4. Front roll stopper through-bolt: 41 ft. lbs. (56 Nm).
      Allow the mounts to support the engine weight before final tightening of the front roll stopper through-bolt.
    5. Torque the power steering pump bracket bolts to 16 ft. lbs. (22 Nm) for 2.0L engine or to 29 ft. lbs. (39 Nm) for 2.5L engine.
    6. Connect the wiring harness connectors to the engine.
      Make certain each terminal is clean and the connector is firmly seated. Do not route wires near hot surfaces or moving parts.
    7. Using a new O-ring lightly lubricated with clean engine oil, connect the high pressure fuel line and torque the bolts to 22 inch lbs. (2.5 Nm).
    8. Check the engine oil drain plug and secure it if necessary, and refill the engine.
    9. Check the transaxle drain plug, tightening it if needed, and refill the transaxle.
    10. Check the radiator and engine drain cocks, closing them if necessary, and refill the cooling system.
    11. Double check all installation items, paying particular attention to loose hoses or hanging wires, loosened nuts, poor routing of hoses and wires.
  3. Connect the negative battery cable. Start the engine and check for leaks.
  4. Attend to all leaks immediately. Adjust the drive belts to the correct tension. Adjust all cables (transaxle, throttle, shift selector) and check the fluid levels. Check the operation of all gauges and dashboard lights.
  5. Road test the vehicle.


  1. Remove the or disconnect the battery and battery tray as follows: 
    The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

    Negative battery cable from the left shock tower

    Shield, by twisting the 4 plastic screws 1 / 4 turn
    Battery blanket heater (if equipped)
    Battery cables
    Battery strap-to-battery hold-down bracket and hold-down bracket bolts
    Battery tray and battery strap
    Air cleaner and inlet duct assembly
    Powertrain Control Module (PCM), move it aside
    Upper/lower radiator hose, radiator and cooling fan
    Automatic transaxle cooler lines (if equipped), plug the lines
    Clutch cable and transaxle shift linkage (if equipped)
    Throttle body linkage and the engine wiring harness
    Heater hoses
    Front wheels
    Right side inner splash shield
    Accessory drive belts
    Both halfshafts
    Exhaust pipe from the exhaust manifold
    Front/rear engine mount brackets, from the body
    Power steering pump and reservoir; move them aside
    Compressor clutch wire lead
    Refrigerant lines from the compressor
    Compressor mounting bolts
    Compressor, plug all openings to prevent moisture contamination
    Engine ground straps and raise the vehicle and install an engine dolly under the vehicle and support engine
    Transaxle and engine mount through-bolts 
    Transaxle/engine assembly
  2. Raise the vehicle slowly allowing the engine/transaxle assembly to remain on the dolly. 

    Click image to see an enlarged view
    Fig. Place the engine/transmission assembly on the cradle as shown
To install:
  1. Position the engine/transaxle assembly under the vehicle and lower the vehicle onto the engine assembly.
  2. Install or connect the following: 

    Right and left mount bolts
    Transaxle mount 

    Click image to see an enlarged view
    Fig. Exploded view of the right side engine mount-all engines

    Click image to see an enlarged view
    Fig. Exploded view of the left side engine mount-Type 1

    Click image to see an enlarged view
    Fig. Exploded view of the left side engine mount-Type 2

    Fig. Exploded view of the rear engine mounting torque bracket-2.0L engine

    Click image to see an enlarged view
    Fig. Exploded view of the front engine mounting torque bracket-2.5L engine
    Both halfshafts
    Transaxle and engine braces
    Splash shields
    Exhaust pipe to the exhaust manifold
    Power steering pump and reservoir
    A/C compressor and torque the mounting bolts to 30 ft. lbs. (41 Nm)
    Refrigerant hoses using new seals
    A/C compressor clutch wire
    Accessory drive belts and adjust them
    Front engine mount
    Inner splash shield
    Front wheels. Torque the lug nuts to 95-100 ft. lbs. (129-135 Nm)
    Clutch cable and linkages, if equipped with a manual transaxle
    Shifter and kickdown linkages, if equipped with an automatic transaxle
    Fuel lines and heater hoses
    Ground straps
    Throttle body electrical connectors
    Throttle body linkage
    Radiator, cooling fan/shroud assembly and hoses
    Transaxle cooler lines to the radiator (if equipped)
  3. Fill the cooling system.
  4. Install the a new oil filter and refill the crankcase, if drained.
  5. Install the or connect the battery tray and the battery as follows:
    DO NOT reattach the negative battery cable remote connection to the left shock tower at this time.

    Battery strap and battery tray
    Battery blanket heater (if equipped)
    Hold-down bracket and battery strap-to-hold-down bracket bolts. Torque the battery hold-down bracket bolt to 10 ft. lbs. (14 Nm)
    Battery cables. Torque the cables to 13 ft. lbs. (17 Nm)

    Air cleaner
    Air inlet duct
  6. Recharge the air conditioning system.
  7. Check to be sure all ducts, hoses, fuel lines and wiring connectors have been properly reattached.
  8. Start the engine, check for oil pressure, and run until operating temperature is reached.
  9. Check for leaks and proper operation.

These details will help.


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