2.4L Engine - Service Information: Removal & Installation Dodge Avenger II facelift

REMOVAL

Note. Camshaft phaser and camshaft sprocket are supplied as an assembly, do not attempt to disassemble.

Scheme 169

1. Remove camshafts. Refer to «CAMSHAFT, ENGINE, REMOVAL»(ref-485475-S14935081432012071300000) .
2. Remove camshaft phaser (2) retaining bolt while holding the camshaft in place with a wrench (1) on the camshaft flats.
3. Remove phaser (2) assembly from camshaft.

Scheme 170

1. Install phaser (2) assembly on camshaft. NOTE: Make sure the dowel is seated in the dowel hole and not in a oil feed hole. The dowel hole is larger than the 4 oil feed holes.
2. Install phaser retaining bolt. Hold camshaft in place with a wrench (1) and tighten bolt to 59 N.m (44 ft. lbs.).
3. Install camshafts. Refer to «CAMSHAFT, ENGINE, INSTALLATION»(ref-485475-S32518628312012071300000) .

INSTALLATION

1. Install flex plate (1).
2. Install washer (2).
3. Install new flex plate bolts (3) and tighten in a criss-cross pattern to 29 N.m (22 ft. lbs.) plus 51° rotation.
4. Install transaxle. Refer to «INSTALLATION»(ref-485525-S03262105032012071300000) .

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Scheme 172

1. Remove oil pan. Refer to «PAN, OIL, REMOVAL»(ref-485475-S01662695162012071300000) .
2. Remove balance shaft assembly. Refer to «PUMP, ENGINE OIL, REMOVAL»(ref-485475-S35786079722012071300000) .
3. Remove ladder frame retaining bolts.
4. Remove ladder frame using pry point cast in the rear of the block (1).
5. To assist in removing the ladder frame another (1) pry point cast in the right side of the block.

1. Position mount (1) and
2. Install retaining bolts (3) and torque to 47 N.m (35 ft. lbs.).
3. Install mount through bolt (2) and torque to 47 N.m (35 ft. lbs.).
4. Install lower silencer (1).
5. Lower vehicle.

Scheme 173

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Scheme 175

1. Remove the air cleaner body (1). Refer to «BODY, AIR CLEANER, REMOVAL»(ref-485475-S36552825552012071300000) .
2. Disconnect and isolate the negative battery cable.
3. Remove the PCM and PCM mounting bracket. Refer to «MODULE, POWERTRAIN CONTROL, REMOVAL»(ref-485482-S06048014282012071300000) .
4. Support the transaxle with a suitable jack.
5. Remove the mount to transaxle bolts (2).
6. Remove the left mount to frame rail fasteners (4).
7. Lower the transaxle to gain access to the mount to frame rail fastener (2).
8. Remove the mount isolator (3).

Scheme 176

Scheme 177

1. Position mount isolator (4) in place and install the bolts hand tight in the following sequence (3), (1) and (2). Tighten the bolts to 54 N.m (40 ft. lbs.) in the following sequence; (2), (1) and (3).
2. Raise the transaxle into position, install bolts (2) and tighten to 110 N.m (81 ft. lbs.).
3. Remove the jack.
4. Install the PCM and PCM mounting bracket. Refer to «MODULE, POWERTRAIN CONTROL, INSTALLATION»(ref-485482-S19357068902012071300000) .
5. Connect the negative battery cable and tighten nut to 5 N.m (45 in. lbs.).
6. Install the air cleaner body (1). Refer to «BODY, AIR CLEANER, INSTALLATION»(ref-485475-S14868414802012071300000) .

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Scheme 180

1. Raise vehicle.
2. Remove lower silencer (1).
3. Remove rear mount retaining bolts (3).
4. Remove rear mount through bolt (1).
5. Remove oxygen sensor (1).
6. Remove rear mount retaining bolts (2).
7. Remove rear mount (1) towards the rear of the vehicle.

1. Position rear mount (1) in place from the rear of the vehicle.
2. Install rear mount retaining bolts (2) and torque to 50 N.m (37 ft. lbs.).
3. Install oxygen sensor (1).
4. Install rear mount retaining bolts (3) and torque to 50 N.m (37 ft. lbs.).
5. Install rear mount through bolt (1) and torque to 47 N.m (35 ft. lbs.).
6. install lower silencer (1).

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Scheme 183

1. Remove coolant reservoir (1) and set aside.
2. Remove power steering line support bracket (3) from engine mount.
3. Support transaxle with a block of wood and a suitable jack.
4. Remove engine mount bracket (2) retaining bolts.
5. Remove engine mount isolator bolts.
6. Remove engine mount isolator (1).

1. Position right engine mount isolator (1).
2. Install engine mount isolator retaining bolts and tighten to 75 N.m (55 ft. lbs.).
3. Install engine mount bracket (2) and tighten bolts (3) to 68 N.m (50 ft. lbs.).
4. Remove jack.
5. Install power steering line support (3) at engine mount.
6. Install coolant reservoir (1).

Scheme 184

The lubrication system is a full-flow filtration, pressure feed type. The balance shaft module (BSM) is mounted below the ladder frame and chain driven by the crankshaft. The BSM consists of a non-serviceable pump, oil pressure relief valve, and a non-serviceable balance assembly.

Scheme 185

Note. Not all blocks have the bolt on timing chain oil squirter. Engine blocks either have a bolt-on oil squirter or a 1.0 mm hole (1) drilled into the oil gallery passage. Engine blocks with the 1.0 mm hole no longer use an oil squirter even though the threaded mounting hole may still be present.

Note. The oil cooler can not be cleaned out. In the event that the engine requires rebuilding or replacement, the oil cooler should be replaced.

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Scheme 187

1. Raise vehicle on hoist.
2. Drain cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .
3. Disconnect oil cooler coolant hoses.
4. Remove oil filter (3).
5. Remove oil cooler connector bolt (2).
6. Remove oil cooler (1).

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Scheme 189

1. Replace oil cooler seal (1).
2. Lubricate seal and position oil cooler to oil filter adapter, aligning notch to tab.
3. Install oil cooler connector bolt (2). Tighten connector bolt to 49 N.m (36 ft. lbs.).
4. Install oil filter (3).
5. Connect oil cooler coolant hose.
6. Lower vehicle.
7. Fill cooling system. Refer to «STANDARD PROCEDURE»(ref-485484-S02211614932012071300000) .

Scheme 190

1. Using a suitable filter wrench, turn oil filter (1) counterclockwise to remove.

Scheme 191

1. Clean and check filter mounting surface. The surface must be smooth, flat and free of debris or pieces of gasket.
2. Lubricate new oil filter gasket.
3. Screw oil filter (1) on until the gasket contacts base. Tighten to 14 N.m (10 ft. lbs.).

Scheme 192

Note. The engine must be HOT when checking oil level.

The best time to check engine oil level is after the engine is at operating temperature. Allow the engine to be shut off for at least 5 minutes before checking oil level.

Scheme 193

Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading. Remove dipstick (1), and observe oil level. Add oil only when the level is at or below the SAFE mark. If the oil level is in the safe (2) range, do not add oil.

Note. Rear plug shown in illustration, other plugs are similar.

1. Use Mopar® Brake Parts Cleaner (or equivalent) sparingly to clean the block.
2. Install the plug (2) flush with the block boss face (1). The plug (2) is correctly installed when it is flush or protruding no more than 1 mm from the block boss face (1).

Scheme 194

The oil pump is integral to the balance shaft module (BSM) (2). The oil pump cannot be disassembled for inspection. The pressure relief valve is serviceable and can be removed and inspected. The BSM can be identified by the plastic end caps (1).

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Scheme 198

1. Rotate engine to TDC (1, 2) on #1 compression stroke.
2. Remove the oil pan. Refer to «PAN, OIL, REMOVAL»(ref-485475-S01662695162012071300000) .
3. Remove the engine timing cover. Refer to «COVER(S), ENGINE TIMING, REMOVAL»(ref-485475-S37960464872012071300000) .
4. Mark the chain (6) and the sprocket (5) for reassembly.
5. Push tensioner piston back into the tensioner body.
6. With piston held back insert tensioner pin (special tool #9703, Pin, Tensioner) (4) into the tensioner body to hold the piston in the retracted position. NOTE: Do not remove sprocket from BSM.
7. Remove BSM mounting bolts. Discard 180 mm bolts, 185 mm bolts can be reused.
8. Lower the back of the BSM and remove the chain (6) from the sprocket (5).
9. Remove BSM from the engine.

Scheme 199

1. Remove timing chain cover. Refer to «COVER(S), ENGINE TIMING, REMOVAL»(ref-485475-S37960464872012071300000) .
2. Remove oil pan. Refer to «PAN, OIL, REMOVAL»(ref-485475-S01662695162012071300000) .
3. Measure the distance between the tensioner body and the guide shoe as shown in illustration.
4. If the distance is 10.1 mm (0.397 in.) or greater, replace the chain.

Scheme 200

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Scheme 202

1. The 185 mm (7.283 in.) length bolts must be checked for stretching. Check the bolts with a straight edge for necking (2). If the bolts are necked down, they must be replaced.
2. Clean BSM mounting holes with Mopar® brake parts cleaner.
3. If chain was removed, align marks on crankshaft sprocket (2) and chain (1).
4. Align marks on oil pump sprocket (5) and chain (4).
5. Install chain on sprocket.
6. Pivot BSM assembly upwards and position on ladder frame.
7. Start BSM mounting bolts by hand. NOTE: Use a three step procedure when tightening BSM mounting bolts. For new 180 mm bolts, go to step 8 . For 185 mm bolts, go to step 9 .
8. Tighten new 180 mm BSM mounting bolts as follows: Tighten to 15 N.m (11 ft. lbs.) in the sequence shown in illustration. Tighten to 33 N.m (24 ft. lbs.) in the sequence shown in illustration. Rotate bolts an additional 90° in the sequence shown in illustration.
9. Tighten 185 mm BSM mounting bolts as follows: Tighten to 15 N.m (11 ft. lbs.) in the sequence shown in illustration. Tighten to 29 N.m (22 ft. lbs.) in the sequence shown in illustration. Rotate bolts an additional 90° in the sequence shown in illustration.
10. Remove tensioner pin (special tool #9703, Pin, Tensioner) (4).
11. Install the engine timing cover. Refer to «COVER(S), ENGINE TIMING, INSTALLATION»(ref-485475-S20501620182012071300000) .
12. Install the oil pan. Refer to «PAN, OIL, INSTALLATION»(ref-485475-S30204973882012071300000) .
13. Fill engine with oil.
14. Start engine and check for leaks.

Scheme 203

1. Disconnect oil temperature sensor (1) electrical connector.
2. Remove sensor (1).

Scheme 204

1. If re-using the oil temperature sensor, coat the threads with Mopar® thread sealant.
2. Install oil temperature sensor (1). Tighten to 18 N.m (160 in. lbs.).
3. Connect electrical connector.

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Scheme 210

1. Remove engine cover (1).
2. Perform fuel system pressure release procedure before attempting any repairs. Refer to «FUEL DELIVERY, GAS, STANDARD PROCEDURE»(ref-485510-S12963059542012071300000) .
3. Remove air cleaner housing (1).
4. Disconnect negative battery cable (1).
5. Disconnect fuel line at rail (3).
6. Remove fuel injector electrical connectors (4).
7. Remove fuel rail retaining bolts and remove fuel rail.
8. Disconnect oil temperature sensor (1).
9. Disconnect variable valve timing solenoid electrical connector.
10. Disconnect intake camshaft position sensor electrical connector.
11. Position harness out of the way.
12. Remove throttle body support bracket (1).
13. Disconnect electronic throttle control electrical connector.
14. Remove wiring harness retainer from the intake manifold (2).
15. Disconnect MAP sensor electrical connector.
16. Disconnect vacuum lines at intake.
17. Remove intake manifold retaining bolts.
18. Remove intake manifold.