2.4L Engine - Service Information: Application Dodge Journey I

SEALER APPLICATION

Mopar® Gasket Maker material should be applied sparingly 1 mm (0.040 in.) diameter or less of sealant to one gasket surface. Be certain the material surrounds each mounting hole. Excess material can easily be wiped off. Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during assembly to prevent smearing material off the location.

Mopar® RTV or ATF RTV gasket material should be applied in a continuous bead approximately 3 mm (0.120 in.) in diameter. For corner sealing and "T" joint locations and waffle pad area, a mm (1/8 or 1/4 in.) drop is placed in the center of the gasket contact area. Uncured sealant may be removed with a shop towel. Components should be torqued in place while the sealant is still wet to the touch (within 10 minutes). The usage of a locating dowel is recommended during assembly to prevent smearing material off the location.

Scheme 190

To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets.

Never use the following to clean gasket surfaces

1. Metal scraper (1).
2. Abrasive pad or paper to clean cylinder block and head.
3. High speed power tool with an abrasive pad or a wire brush (2,3).

Note. Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.

Only use the following for cleaning gasket surfaces

1. Solvent or a commercially available gasket remover
2. Plastic or wood scraper (4).

Sealing surfaces must be free of grease or oil residue. Clean surfaces with Mopar® brake parts cleaner (or equivalent).

Scheme 191

Using a blunt tool (3) such as a drift and a hammer, strike the bottom edge of the cup plug (5). With the cup plug rotated, grasp firmly with pliers or other suitable tool (2) and remove plug (5).

Thoroughly clean inside of cup plug hole in cylinder head. Be sure to remove old sealer. Lightly coat inside of cup plug hole with Mopar® Stud and Bearing Mount (or equivalent). Make certain the new plug is cleaned of all oil or grease. Using proper drive plug, drive plug into hole so that the sharp edge of the plug is at least 0.5 mm (0.020 in.) inside the lead-in chamfer.

It is not necessary to wait for curing of the sealant. The cooling system can be refilled and the vehicle placed in service immediately.

Scheme 192

1. Use Mopar® Brake Parts Cleaner (or equivalent) sparingly to clean plug and block.
2. Coat plug threads with Mopar® Thread Sealant (or equivalent).
3. Install plug (2). The plug (2) is correctly installed when it is protruding 1 mm to flush with the block boss face (1).

Scheme 193

Engine crankshaft bearing clearances can be determined by use of Plastigage or equivalent. The following is the recommended procedure for the use of Plastigage

1. Remove oil film from surface to be checked. Plastigage is soluble in oil.
2. Place a piece of Plastigage (1) across the entire width of the journal. (In addition, suspected areas can be checked by placing the Plastigage in the suspected area). Torque the bearing cap bolts of the bearing being checked to the proper specifications.
3. Remove the bearing cap and compare the width of the flattened Plastigage with the scale provided on the package. Locate the band closest to the same width. This band shows the amount of clearance. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. Compare clearance measurements to specs found in «Engine - Specifications»(ref-353574-S10451143612010011200000) . Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for the specifications you are checking.
4. Install the proper crankshaft bearings to achieve the specified bearing clearances.

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1. Remove engine cover (1) by pulling upwards.

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1. Remove engine cover (1).
2. Perform fuel pressure release procedure, then disconnect and remove fuel line (3). Refer to «Fuel System/Fuel Delivery - Standard Procedure»(ref-353596-S39204571612010011200000) .
3. Remove make-up air hose (2).
4. Remove air cleaner housing assembly (1). See «Engine/Air Intake System/BODY, Air Cleaner - Removal»(ref-353574-S13740738892010011200000) .
5. Disconnect negative battery cable (1).
6. Discharge air conditioning system, if equipped.
7. Drain cooling system.
8. Remove coolant reservoir (1).
9. Remove power steering reservoir (2).
10. Remove power steering line support at engine mount (1).
11. Remove power steering pump and set aside.
12. Remove coolant hoses from coolant adapter (3).
13. Disconnect coolant temperature sensor connector (1) and capacitor connector (2).
14. Disconnect coils (1), injectors (4), cam sensors, oil temperature sensor, and oil control valve electrical connectors and reposition harness.
15. Remove PCV hose (5) from valve cover.
16. Remove harness from intake (2).
17. Remove throttle body support bracket (1).
18. Remove vacuum lines from throttle body and intake manifold.
19. Disconnect electronic throttle control and manifold flow control valve electrical connectors.
20. Remove dipstick.
21. Remove intake bolts and remove intake.
22. Disconnect coolant temperature sensor at block, knock sensor, oil pressure sensor, generator, starter, block heater (if equipped), A/C compressor (if equipped), and block ground.
23. Remove accessory drive belt.
24. Raise vehicle.
25. Remove front splash shield.
26. Drain oil (2).
27. Remove exhaust pipe to exhaust manifold bolts (1).
28. Disconnect oxygen sensor connector (3).
29. Remove exhaust manifold heat shield (2).
30. Remove exhaust manifold.
31. Remove inspection cover (1) and mark torque converter to flywheel.
32. On vehicles equipped with an automatic transaxle, remove torque converter bolts (1).
33. On vehicles equipped with an manual transaxle, remove modular clutch bolts (1).
34. Remove lower bellhousing bolts (2).
35. Remove A/C compressor (1) from engine and set aside.
36. Remove generator and lower idler pulley.
37. Disconnect CKP sensor (2) electrical connector.
38. Remove right engine mount bracket retaining bolts (4).
39. Remove power steering hose hold down (3).
40. Remove retaining nuts (2) and position mount bracket (1) aside.
41. Remove intake oil control valve to prevent damage.
42. Install engine lift chain to rear lift bracket and bolt to cylinder head (1) in the front.
43. Hoist engine from vehicle.
44. Separate engine and transmission.

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1. Position engine cover (1) over mounting studs.
2. Seat the cover on the rear studs by pushing downwards.
3. Push downward on the front of the cover to seat the front studs.

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1. Connect engine lift chain (1) to engine.
2. Slowly lower engine assembly in to position.
3. Position right mount bracket (1) and install bolts (4).
4. Install retaining nuts (2) and tighten nuts (2) to 30 N.m (22 ft. lbs.).
5. Tighten bolts (4) to 50 N.m (37 ft. lbs.).
6. Install A/C compressor mounting bracket (2).
7. Install A/C compressor (1) and connect lines.
8. Install exhaust manifold and upper lower heat shields (Refer to «Manifolds»(ref-353574-S18075810172010011200000) ).
9. Install oxygen sensor and connect electrical connector.
10. Install Ground strap (1) near right strut tower.
11. Raise vehicle.
12. Install crankshaft position sensor (CKP) (2).
13. Connect CKP electrical connector (2).
14. Install manifold to exhaust pipe bolts (1) and tighten bolts.
15. Install generator.
16. Install lower bell housing bolts (2) and tighten.
17. Align torque converter and flex plate mark. Install torque converter bolts (1) and tighten.
18. Install inspection cover (1).
19. Install new oil filter (1).
20. Lower vehicle.
21. Install upper idler pulley.
22. Install power steering pump.
23. Install power steering line support bracket (1).
24. Install power steering pump.
25. Install accessory drive belt.
26. Connect electrical connectors at block ground, starter, A/C compressor, knock sensor, oil pressure sensor, generator, coolant temperature sensor at block, and block heater.
27. Install intake manifold and tighten bolts to 24 N.m (18 ft. lbs.) as shown in illustration.
28. Install throttle body support bracket (1).
29. Connect manifold flow control valve and electronic throttle control electrical connectors.
30. Insert wiring harness retainer into intake manifold (2).
31. Install engine oil dip stick.
32. Install PCV hose (5).
33. Install vacuum lines at throttle body and intake manifold.
34. Install intake air tube on throttle body.
35. Connect engine harness electrical connectors.
36. Install coolant hoses at coolant adapter (3).
37. Install coolant reservoir (1) and connect hose.
38. Connect fuel line to fuel rail (3).
39. Connect negative battery cable (1).
40. Install air cleaner housing (1) and connect inlet air hose (Refer to «Air Intake System»(ref-353574-S03437942732010011200000) ).
41. Fill with coolant.
42. 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.
43. Evacuate the refrigerant system (refer to appropriate HVAC article).
44. Charge the refrigerant system (refer to appropriate HVAC article).
45. Start engine and check for leaks.
46. Install engine cover (1).

GENERAL SPECIFICATIONS

CYLINDER BLOCK

PISTONS

PISTON RINGS

CONNECTING ROD

CRANKSHAFT

CYLINDER HEAD CAMSHAFT BEARING BORE DIAMETER

CAMSHAFT

CYLINDER HEAD

VALVE SEAT

VALVE GUIDE

VALVES

VALVE MARGIN

VALVE STEM TIP

VALVE STEM TO GUIDE CLEARANCE

VALVE SPRINGS

OIL PRESSURE