4.0L Engine - Service Information: Removal & Installation Dodge Nitro I

ENGINE ASSEMBLY-INSTALLATION

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1. Install special tool #8534 B, engine lifting bracket (2) to the right rear of the cylinder head and install a bolt into the inner most bolt hole (5) next to the bracket (5). see scheme 26 1 - LIFTING CHAIN 2 - UPPER TIMING CHAIN COVER 3 - POWER STEERING PUMP 4 - THERMOSTAT HOUSING
2. Connect a engine hoisting chain (1) to the left timing chain cover (2) lifting point and the engine lifting bracket. see scheme 27
3. Carefully install the engine into the engine bay area and complete the union with the transmission.
4. Properly route the engine wiring harness behind the engine and tighten the accessible transmission bolts to 68 N.m (50 ft. lbs.).
5. Connect the ground strap (1) at the transmission housing.
6. Install the remaining transmission housing bolts (2) and tighten to 68 N.m (50 ft. lbs.).
7. Install the engine mounting fasteners (1) and tighten to 101 N.m (75 lbs. ft.). 1 - Electrical Connector 2 - Mounting Bolt 3 - Coil
8. Properly position the right engine harness and connect the oxygen sensor, knock sensor, EGR, fuel injector and ignition coil harness connectors (1).
9. Connect the capacitor (3) and ground strap (3) to the right cylinder head cover.
10. Properly position the left engine harness and fuel injector harness connectors.
11. Connect the coolant temperature, cam position (1), oil pressure sensor harness connectors.
12. Connect the oxygen sensor, and the ground wire, to the cylinder head cover.
13. Install the torque converter bolts (2). Tighten bolts to 75 N.m (55 lbs. ft.).
14. Connect the heater hose.
15. Install the right intake manifold support braces.
16. Install the torque converter inspection plate (1). Tighten bolts to 12 N.m (105 lbs. in.)
17. Install the upper intake manifold (Refer to «INSTALLATION»(ref-306143-S05495232132008120900000) ).
18. Connect the upper radiator hose.
19. Install the crankshaft position sensor (2) (Refer to «INSTALLATION»(ref-306144-S07640348432008120900000) ).
20. Connect the engine block heater (if equipped).
21. Connect the oil cooler hose (2) at the cooler.
22. Connect the oil cooler hose (3) at the cooler.
23. Connect the lower radiator hose (5).
24. Install new oil filter.
25. Install the starter (1) and spacer plate (Refer to «INSTALLATION»(ref-306163-S19299772542008120900000) ).
26. Connect the left (1) and right exhaust pipe to the exhaust manifold (2).
27. Connect the oxygen sensors (1).
28. Connect the generator electrical connectors (2) (Refer to «INSTALLATION»(ref-306161-S23448537052008120900000) ).
29. Fill the cooling system to the proper level using the appropriate coolant.
30. Fill engine crankcase with proper oil to correct level (Refer to «SPECIFICATIONS»(ref-306134-S19102644582008120900000) ).
31. Install the P/S pump (2).
32. Install the A/C lines (1, 3).
33. Evacuate and recharge air conditioning.
34. Install the hood.
35. Connect the negative battery cable (2).
36. Start engine and run until operating temperature is reached.
37. Check all fluid levels and properly fill.

INSTALLATION

1. Install the air filter element (2) into air box.
2. Seat cover (1) onto element housing and lock the front latches (6).

REMOVAL

1. Disconnect the CCV hose (5) at the element housing (1).
2. Loosen two clamps (2), disengage and reposition the air inlet hose (4).
3. Pull housing up and off of the three locating grommets.
4. Disengage the air inlet duct and remove housing (1) from vehicle.

1. Align the housing (1) with the air inlet duct and locating grommets in the wheel housing.
2. Properly fit the housing (1) while engaging the air inlet duct. Lift up on the air inlet duct to engage lock tabs.
3. Install the air inlet hose (4) to the housing (1) and throttle body. Tighten clamps (2).
4. Connect the CCV hose (5) to housing.

1. Drain cooling system.
2. Raise vehicle on hoist.
3. Disconnect coolant hose (3) from oil cooler (1).
4. Disconnect coolant hoses (2) from oil cooler (1).
5. Remove oil filter.
6. Remove oil cooler attaching fastener from center of oil cooler.
7. Remove oil cooler (1).

1. Position oil cooler to fitting on oil pan. NOTE: Remove all oil and debris from the seal retainer surface. The cut out section of the oil cooler seal retainer flange (top), must be aligned with the tab on the oil pan. The oil cooler must be prevented from turning during the tightening sequence.
2. Install oil cooler (1) attaching fastener and tighten to 61 N.m (45 ft. lbs.).
3. Install oil filter and tighten to 12 N.m (106 in. lbs.).
4. Connect coolant hose (2) to oil cooler (1).
5. Connect coolant hose (3) to oil cooler (1).
6. Fill cooling system.