Breeze, Cirrus, Sebring Convertible and Sedan, Stratus Sedan, 1999-2005

Engine

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Removal & Installation



2.0L And 2.5L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
    NOTE
    The transaxle must be removed before removing the engine. They will not come out as a unit.

  2.  
  3. Drain the engine coolant.
  4.  
  5. Drain the engine oil
  6.  
  7. Drain the transmission oil.
  8.  
  9. Properly relieve the fuel system pressure.
  10.  
  11. Remove or disconnect the following:
    NOTE
    All wires and connectors should be labeled at the time of engine removal. This will save time during assembly.


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


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



    Hood
     
    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
     

  12.  
  13. 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.
    WARNING
    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
     
    Engine
     



    Click image to see an enlarged view

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



    Click image to see an enlarged view

    Fig. Exploded view of the right-side engine mount-2.5L engine

  14.  

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.  

  2.  
  3. Torque the engine mount nuts and bolts as follows:
    1. Right-side mount-to-engine nut and bolt: 63 ft. lbs. (86 Nm).
    2.  
    3. Right-side mount through-bolt: 71-85 ft. lbs. (98-118 Nm).
    4.  
    5. Rear roll stopper through-bolt: 32 ft. lbs. (44 Nm).
    6.  
    7. Front roll stopper through-bolt: 41 ft. lbs. (56 Nm).
      NOTE
      Allow the mounts to support the engine weight before final tightening of the front roll stopper through-bolt.

    8.  
    9. 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.
    10.  
    11. Connect the wiring harness connectors to the engine.
      WARNING
      Make certain each terminal is clean and the connector is firmly seated. Do not route wires near hot surfaces or moving parts.

    12.  
    13. 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).
    14.  
    15. Check the engine oil drain plug and secure it if necessary, and refill the engine.
    16.  
    17. Check the transaxle drain plug, tightening it if needed, and refill the transaxle.
    18.  
    19. Check the radiator and engine drain cocks, closing them if necessary, and refill the cooling system.
    20.  
    21. Double check all installation items, paying particular attention to loose hoses or hanging wires, loosened nuts, poor routing of hoses and wires.
    22.  

  4.  
  5. Connect the negative battery cable. Start the engine and check for leaks.
  6.  
  7. 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.
  8.  
  9. Road test the vehicle.
  10.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure using the recommended procedure. Disconnect the fuel line quick-connect fitting from the fuel rail by squeezing the retainer tabs together and pulling the fuel tube/quick-connect fitting assembly off the fuel tube nipple.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the cooling system.
  8.  
  9. Recover the A/C refrigerant.
  10.  
  11. Place the ignition switch in the OFF unlocked position and turn OFF all accessories.
  12.  
  13. Turn the steering wheel to the extreme left position.
  14.  
  15. Remove the or disconnect the battery and battery tray as follows:
    NOTE
    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
     
    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

    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



    Click image to see an enlarged view

    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

     
    Transaxle/engine assembly
     

  16.  
  17. 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

  18.  

To install:

  1. Position the engine/transaxle assembly under the vehicle and lower the vehicle onto the engine assembly.
  2.  
  3. 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



    Click image to see an enlarged view

    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)
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Install the a new oil filter and refill the crankcase, if drained.
  8.  
  9. Install the or connect the battery tray and the battery as follows:
    NOTE
    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)
     
    Battery
     
    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)
     



    Shield
     
    PCM
     
    Air cleaner
     
    Air inlet duct
     

  10.  
  11. Recharge the air conditioning system.
  12.  
  13. Check to be sure all ducts, hoses, fuel lines and wiring connectors have been properly reattached.
  14.  
  15. Start the engine, check for oil pressure, and run until operating temperature is reached.
  16.  
  17. Check for leaks and proper operation.
  18.  

2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the cooling system.
  8.  
  9. Recover the A/C refrigerant.
  10.  
  11. 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
     

  12.  
  13. 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.
     

  14.  
  15. 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.

    Click image to see an enlarged view

    Fig. Do not remove the flywheel bolt shown, or you will damage the flywheel

  16.  
  17. Remove the engine mount bracket, as follows:
    1. Support the engine with a suitable jack.
    2.  
    3. Remove the special tools that were attached during transaxle removal
    4.  
    5. Hold the engine assembly with a chain block or similar tool.
    6.  
    7. 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.
    8.  

  18.  
  19. Remove the engine mount stopper.
  20.  
  21. Make sure that all cables, hoses and electrical connections are disconnected, slowly raise the engine up and out of the engine compartment.
  22.  

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.

    Click image to see an enlarged view

    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.  
  3. Fill the engine with clean oil and replace the filter.
  4.  
  5. Fill the cooling system to the proper level.
  6.  
  7. Recharge the A/C system with the proper refrigerant.
  8.  
  9. Start the vehicle, check for leaks and repair if necessary.
  10.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the cooling system.
  8.  
  9. Recover the A/C refrigerant.
  10.  
  11. 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

    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 rear engine mounting torque bracket-2.4L engines

     
    Rear mount bracket from the transmission
     
    Structural cover and torque reaction bracket

    Click image to see an enlarged view

    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
     

  12.  
  13. Loosen the cradle engine mounts and lower the engine/transmission assembly onto the dolly.
  14.  
  15. Remove the vertical engine mount bolts
  16.  
  17. Slowly raise the vehicle and make certain that the cradle is positioned properly.
  18.  
  19. Secure the engine/transmission assembly to the cradle and remove the assembly.

    Click image to see an enlarged view

    Fig. Place the engine/transmission assembly on the cradle as shown

  20.  

To install:

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

    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 rear engine mounting torque bracket-2.4L engines

  4.  
  5. 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

    Click image to see an enlarged view

    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
     

  6.  
  7. Fill the engine with clean oil.
  8.  
  9. Fill the cooling system to the proper level.
  10.  
  11. Recharge the A/C system.
  12.  
  13. Start the vehicle, check for leaks and repair if necessary.
  14.  

2.7L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the cooling system.
  8.  
  9. Recover the A/C refrigerant.
  10.  
  11. Remove or disconnect the following:

    Negative battery cable
     
    Throttle body air inlet hose
     
    Air cleaner assembly
     
    Both front wheels and splash shields
     
    Lower front fascia from the crossmember
     
    Lower air shield from the crossmember
     
    Front fascia
     
    Upper radiator crossmember
     
    Upper and lower radiator hoses
     
    Transmission oil cooler lines
     
    A/C lines from the condenser
     
    Radiator, fan and A/C condenser
     
    Transmission electrical harness connectors
     
    Transmission shift cable
     
    Engine electrical harness from the Powertrain Control Module (PCM) and bulkhead connectors
     
    Antilock Brake System (ABS) brake module from the lower radiator crossmember
     
    Brake line from the lower radiator crossmember
     
    Both halfshafts
     
    Front engine mount through bolt
     
    Front engine mount from the lower radiator crossmember
     
    Lower radiator crossmember
     
    Drive belts
     
    Power steering pump and bracket. Do not disconnect the lines
     
    Heater return hose from the right front frame rail
     
    A/C compressor electrical connectors and reposition the compressor
     
    Structural collar
     
    Exhaust system cross under pipe
     
    Rear engine mount and transaxle bracket
     
    Torque converter housing cover and match mark the bolts
     
    Positive battery cable from the Power Distribution Center (PDC)
     
    Ground cable from the left side transaxle mount bracket
     
    Throttle and speed control cables
     
    Coolant overflow hose
     
    Heater hose
     
    Ground strap from the right shock tower
     
    Fuel lines
     
    Brake booster and vacuum purge hoses
     
    Engine ground straps
     

  12.  
  13. Loosen the cradle engine mounts and lower the engine/transmission assembly onto the dolly.
  14.  
  15. Remove the vertical engine mount bolts
  16.  
  17. Slowly raise the vehicle and make certain that the cradle is positioned properly.
  18.  
  19. Secure the engine/transmission assembly to the cradle and remove the assembly.
  20.  

To install:

  1. Position the engine/transmission assembly under the vehicle and slowly lower the vehicle into position.
  2.  
  3. Continue to the lower the vehicle until the right side engine mount and left side transaxle mount are properly aligned.
  4.  
  5. Install or connect the following:

    Mounting bolts and torque them to 45 ft. lbs. (61 Nm).
     
    Raise the vehicle and remove the cradle
     
    Engine ground straps
     
    Brake booster and vacuum purge hoses
     
    Fuel lines
     
    Ground strap to the right shock tower
     
    Heater hose
     
    Coolant overflow hose
     
    Throttle and speed control cables
     
    Ground cable to the left transaxle mount bracket
     
    Positive battery cable to the PDC
     
    Torque converter bolts and cover
     
    Rear engine mount and transaxle bracket
     
    Exhaust system cross under pipe
     
    Structural collar
     
    A/C compressor to the bracket
     
    A/C compressor clutch electrical connectors
     
    Heater return hose to the right side frame rail
     
    Power steering pump and bracket
     
    Drive belts
     
    Lower radiator crossmember
     
    Front engine mount to the lower radiator crossmember
     
    Both halfshafts
     
    Brake line to the lower radiator crossmember
     
    ABS module to the lower radiator crossmember
     
    Engine electrical harness to the PCM and bulkhead connectors
     
    Transmission shift cable
     
    Transmission electrical harness connectors
     
    Radiator, fan and A/C condenser
     
    A/C lines to the condenser
     
    Transmission oil cooler lines
     
    Upper and lower radiator hoses
     
    Upper radiator crossmember
     
    Front bumper fascia and lower air shield
     
    Splash shields and both front wheels
     
    Air cleaner assembly and throttle body air inlet hose
     
    Negative battery cable
     

  6.  
  7. Fill the engine with clean oil and replace the filter.
  8.  
  9. Fill the cooling system to the proper level.
  10.  
  11. Recharge the A/C system with the proper refrigerant.
  12.  
  13. Start the vehicle, check for leaks and repair if necessary.
  14.  

 
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