Avenger 2008

Engine 1

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Removal & Installation



2.4L Engine

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

  1. Remove engine cover (1).

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    Fig. Remove engine cover (1)

  2.  
  3. Perform fuel pressure release procedure, then disconnect and remove fuel line (3).

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    Fig. Disconnect and remove fuel line (3)

  4.  
  5. Remove make-up air hose (2).
  6.  
  7. Remove air cleaner housing assembly (1).

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    Fig. Remove air cleaner housing assembly (1)

  8.  
  9. Disconnect negative battery cable.
  10.  
  11. Discharge air conditioning system, if equipped.
  12.  
  13. Drain cooling system.
  14.  
  15. Remove coolant reservoir (1).

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    Fig. Remove coolant reservoir (1)

  16.  
  17. Remove power steering reservoir (2).
  18.  
  19. Remove power steering line support at engine mount (1).

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    Fig. Remove power steering line support at engine mount (1)

  20.  
  21. Remove power steering pump and set aside.
  22.  
  23. Remove coolant hoses from coolant adapter (3).

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    Fig. Remove coolant hoses from coolant adapter (3)

  24.  
  25. Disconnect coolant temperature sensor connector (1) and capacitor connector (2).
  26.  
  27. Disconnect coils (1), injectors (4), cam sensors, oil temperature sensor, and oil control valve electrical connectors and reposition harness.

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    Fig. Disconnect coils (1), injectors (4), cam sensors, oil temperature sensor, and oil control valve electrical connectors and reposition harness

  28.  
  29. Remove PCV hose (5) from valve cover.
  30.  
  31. Remove harness from intake (2).

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    Fig. Remove harness from intake (2)

  32.  
  33. Remove throttle body support bracket (1).
  34.  
  35. Remove vacuum lines from throttle body and intake manifold.
  36.  
  37. Disconnect electronic throttle control and manifold flow control valve electrical connectors.
  38.  
  39. Remove dipstick.
  40.  
  41. Remove intake bolts and remove intake manifold.

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    Fig. Remove intake bolts and remove intake manifold

  42.  
  43. Disconnect coolant temperature sensor at block, knock sensor, oil pressure sensor, alternator, starter, block heater (if equipped), A/C compressor (if equipped), and block ground.
  44.  
  45. Remove accessory drive belt.
  46.  
  47. Raise vehicle.
  48.  
  49. Remove front splash shield.
  50.  
  51. Drain the engine oil.
  52.  
  53. Remove exhaust pipe to exhaust manifold bolts (1).

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    Fig. Remove exhaust pipe to exhaust manifold bolts (1)

  54.  
  55. Disconnect oxygen sensor connector (3).
  56.  
  57. Remove exhaust manifold heat shield (2).
  58.  
  59. Remove exhaust manifold.
  60.  
  61. Remove inspection cover (1) and mark torque converter to flywheel.

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    Fig. Remove inspection cover (1) and mark torque converter to flywheel

  62.  
  63. On vehicles equipped with an automatic transaxle, remove torque converter bolts (1).
  64.  
  65. On vehicles equipped with an manual transaxle, remove modular clutch bolts (1).
  66.  
  67. Remove lower bellhousing bolts (2).

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    Fig. Remove lower bellhousing bolts (2)

  68.  
  69. Remove A/C compressor (1) from engine and set aside.

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    Fig. Remove A/C compressor (1) from engine and set aside

  70.  
  71. Remove alternator and lower idler pulley.
  72.  
  73. Disconnect Crankshaft Position (CKP) sensor (2) electrical connector.

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    Fig. Disconnect CKP sensor (2) electrical connector

  74.  
  75. Remove right engine mount bracket retaining bolts (4).

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    Fig. Remove right engine mount bracket retaining bolts (4)

  76.  
  77. Remove power steering hose hold down (3).
  78.  
  79. Remove retaining nuts (2) and position mount bracket (1) aside.
  80.  
  81. Remove intake oil control valve to prevent damage.
  82.  
  83. Install engine lift chain to rear lift bracket and bolt to cylinder head (1) in the front.

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    Fig. Install engine lift chain to rear lift bracket and bolt to cylinder head (1) in the front

  84.  
  85. Hoist engine from vehicle.
  86.  
  87. Separate engine and transmission.
  88.  

To install:

  1. Connect engine lift chain to engine.
  2.  
  3. Slowly lower engine assembly in to position.
  4.  
  5. Position right mount bracket (2) and install bolts (3).

    Click image to see an enlarged view

    Fig. Position right mount bracket (2) and install bolts (3)

  6.  
  7. Install mounting bolts at the right engine mount bolts and tighten bolts to 87 ft. lbs. (118 Nm).
  8.  
  9. Install through bolt (4) and tighten to 87 ft. lbs. (118 Nm).
  10.  
  11. Install A/C compressor mounting bracket.
  12.  
  13. Install A/C compressor and connect lines.
  14.  
  15. Install exhaust manifold and upper lower heat shields).
  16.  
  17. Install oxygen sensor and connect electrical connector.
  18.  
  19. Install ground strap near right strut tower.
  20.  
  21. Raise vehicle.
  22.  
  23. Install Crankshaft Position Sensor (CKP).
  24.  
  25. Connect CKP electrical connector.
  26.  
  27. Install manifold to exhaust pipe bolts and tighten bolts.
  28.  
  29. Install alternator.
  30.  
  31. Install lower bell housing bolts and tighten.
  32.  
  33. Align torque converter and flex plate mark.
  34.  
  35. Install torque converter bolts and tighten.
  36.  
  37. Install inspection cover.
  38.  
  39. Install new oil filter.
  40.  
  41. Lower vehicle.
  42.  
  43. Install upper idler pulley.
  44.  
  45. Install power steering pump.
  46.  
  47. Install power steering line support bracket.
  48.  
  49. Install power steering pump.
  50.  
  51. Install accessory drive belt.
  52.  
  53. Connect electrical connectors at block ground, starter, A/C compressor, knock sensor, oil pressure sensor, alternator, coolant temperature sensor at block, and block heater.
  54.  
  55. Install intake manifold and tighten bolts to 18 ft. lbs. (24 Nm) in sequence.

    Click image to see an enlarged view

    Fig. Install intake bolts in sequence

  56.  
  57. Install throttle body support bracket.
  58.  
  59. Connect manifold flow control valve and electronic throttle control electrical connectors.
  60.  
  61. Insert wiring harness retainer into intake manifold.
  62.  
  63. Install engine oil dip stick.
  64.  
  65. Install PCV hose.
  66.  
  67. Install vacuum lines at throttle body and intake manifold.
  68.  
  69. Install intake air tube on throttle body.
  70.  
  71. Connect engine harness electrical connectors.
  72.  
  73. Install coolant hoses at coolant adapter.
  74.  
  75. Install coolant reservoir and connect hose.
  76.  
  77. Connect fuel line to fuel rail.
  78.  
  79. Connect negative battery cable.
  80.  
  81. Install air cleaner housing and connect inlet air hose.
  82.  
  83. Fill with coolant.
  84.  
  85. 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.

  86.  
  87. Evacuate the refrigerant system.
  88.  
  89. Charge the refrigerant system.
  90.  
  91. Start engine and check for leaks.
  92.  
  93. Install engine cover.
  94.  

 
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