2.0L 4-CYL Engine - VIN [C]: Removal & Installation Dodge Stratus I

REMOVAL & INSTALLATION

Note. When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Place mating marks on engine hood and other major assemblies before removal.

Removal

When disconnecting a quick-connect fitting, the retainer will remain on the fuel tube nipple.

1. Disconnect negative cable from auxiliary jumper terminal.
2. Perform Fuel Pressure Release Procedure. Refer to «FUEL PRESSURE RELEASE»(ref-54166-S18221671892001011700000) .
3. Squeeze retainer tabs together and pull fuel tube/quick-connect fitting assembly off of fuel tube nipple. The retainer will remain on fuel tube.

Installation

1. Using a clean lint free cloth, clean fuel tube nipple and retainer.
2. Prior to connecting fitting to the fuel tube, coat fuel tube nipple with clean 30 weight engine oil.
3. Push quick-connect fitting over fuel tube until retainer seats and a click is heard. The quick-connect fitting has windows in the sides of the casing. When the fitting completely attaches to the fuel tube, the retainer locking ears and fuel tube shoulder are visible in the windows. If they are not visible, the retainer was not properly installed. Do not rely upon the audible click to confirm a secure connection.
4. Ensure locking ears on retainer and the shoulder (stop bead) on the fuel tube are completely visible in the quick-connect fitting windows. Do not rely upon the audible click to confirm a secure connection. Always pull on the line and fitting to ensure that retainer is seated.
5. Verify connection by pulling on the lines. If fitting locks in place, the connection is secure.
6. Use DRB scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.

1. Release fuel system pressure. Refer to «FUEL PRESSURE RELEASE»(ref-54166-S18221671892001011700000).
2. From inside trunk, disconnect fuel pump module wiring jumper from main body harness. The 4 pin connector is located under the trunk mat on the left side of trunk near the base of the shock tower. Locate body grommet for jumper near base of rear seat. Push grommet out and feed jumper completely through hole in body.
3. Remove fuel cap slowly to release tank pressure.
4. With vehicle on a hoist, drain fuel from tank. Support fuel tank with a support such as a transmission jack stand.
5. Position a fuel approved container, with a capacity of at least 16 gallons, under the drain plug located on the bottom left edge of the tank.
6. Remove drain plug and allow fuel to drain.
7. When tank is no longer draining, install drain plug. Tighten plug to 32 in. lbs.
8. Remove drivers side fuel tank strap. Loosen, do not remove, passenger side fuel tank strap allowing fuel tank fill neck to touch rear suspension crossmember.
9. Disconnect fuel lines from fuel pump module (Scheme 5) These are quick connect fittings. Refer to «FUEL TUBES AND QUICK CONNECT FITTINGS»(ref-54166-S01536251872010033100000).
10. Disconnect fuel supply line from the fuel brake module.
11. Remove fuel filter (Scheme 6)

Scheme 4

The fuel supply (to filter) tube, return tube (to pump module) are permanently attached to the fuel filter. The ends of the fuel supply and return tubes have different size quick-connect fittings. The larger quick-connect fitting connects to the large nipple (supply side) on the fuel pump module. The smaller quick-connect fitting attaches to the small nipple (return side) on the fuel pump module.

1. Apply a light coating of clean 30 weight engine oil to the fuel filter nipples. Install fuel tubes. Refer to «FUEL TUBES AND QUICK CONNECT FITTINGS»(ref-54166-S01536251872010033100000) .
2. Install fuel tank, filter and tank straps. Torque tank strap bolts 23 N.m (to 250 in. lbs.). Make sure pump module harness grommet is installed in body as tank is raised into position.
3. Lower vehicle and connect pump module connector.
4. Fill tank with fuel.
5. Connect negative cable to auxiliary jumper terminal.

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-54166-S18221671892001011700000) . Disconnect and remove battery and tray (if necessary). Set Powertrain Control Module (PCM) aside. Drain cooling system. Remove upper radiator hose and remove radiator fan module. Remove lower radiator hose.
2. On automatic transmission models, disconnect transmission cooler lines and plug cooler lines. On manual transmission models, disconnect clutch cable and transmission shift linkage. Remove power hop damper. On all models, disconnect throttle body linkage. Disconnect engine wiring harness. Disconnect heater hoses.
3. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Hoist vehicle and remove right inner splash shield. Remove accessory drive belts. Remove axle shafts. See «AXLE SHAFTS - FRONT»(ref-43051) article. Disconnect exhaust pipe from manifold. Remove front engine mount bracket from body.
4. Lower vehicle. Remove air cleaner assembly. Remove power steering pump and reservoir and set them aside. Remove A/C compressor. Remove ground straps to body. Raise vehicle enough to allow Engine Dolly and Cradle (6135 and 6710) to be installed under vehicle.
5. Loosen engine support posts to allow movement for positioning onto engine locating holes and flange on the engine bedplate. Lower vehicle and position cradle until the engine is resting on support posts.
6. Tighten mounts to cradle frame. This will keep support posts from moving when removing or installing engine and transmission. Install safety straps around the engine-to-cradle frame, tighten straps and lock them into position.
7. Raise vehicle enough to see if straps are tight enough to hold cradle assembly to engine. Lower vehicle so ONLY the weight of the engine and transmission is on the cradle assembly. Remove engine and transmission mount through bolts.
8. Raise vehicle slowly. It may be necessary to move the engine/transmission assembly with the cradle to allow for removal around body flanges. Remove engine.

1. Position engine/transmission assembly under the vehicle. Slowly lower the vehicle over the engine/transmission. Align engine and transmission mounts with attaching points. Install mounting bolts at the right engine and left transmission mounts.
2. Remove safety straps from engine and transmission assembly. Raise the vehicle and remove the engine dolly and cradle. Install axle shafts. See «AXLE SHAFTS - FRONT»(ref-43051) article. Install transmission and engine braces. Install splash shields. Connect exhaust system.
3. Install power steering pump and reservoir, and A/C compressor and hoses. Install accessory drive belts. Install front engine mount and inner splash shield. Install front wheels.
4. On models with manual transmission, connect clutch cable and shifter linkage. Install power hop damper. On models with automatic transmission, connect shifter and kickdown linkage. On all models, connect fuel line and heater hoses. Install ground straps. Connect engine and throttle body connections and harnesses.
5. Connect throttle body linkage. Install radiator and shroud assembly. Connect or install radiator hoses and fill cooling system. Install battery tray and battery. Install Powertrain Control Module (PCM) into position.
6. Install air cleaner assembly. Install oil filter and refill oil. Adjust transmission linkage, if necessary, after starting engine and warming to it operating temperature.

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-54166-S18221671892001011700000). Disconnect negative battery cable. Remove air intake resonator. Disconnect fuel supply line quick-connect at fuel tube assembly.
2. Remove fuel rail assembly attaching screws and remove fuel rail from engine. Cover injector holes to prevent entry of foreign material. WARNING: Wrap shop towels around hose to catch any fuel spillage. NOTE: To prevent damage, DO NOT set fuel injectors on their tips.
3. Remove accelerator, kickdown and speed control cables from throttle lever and bracket. Disconnect Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors.
4. Disconnect vacuum hoses from throttle body. Disconnect Manifold Absolute Pressure (MAP) sensor and air intake temperature sensor electrical connectors. Disconnect vapor and brake booster hoses.
5. Disconnect knock sensor connector and wiring harness from tab located on intake manifold. Disconnect wiring at starter. Remove transmission-to-throttle body support bracket fasteners at throttle body and loosen fastener at transmission end. Remove throttle body.
6. Remove EGR tube bolts at valve and at intake manifold. Remove tube from engine. Remove intake manifold-to-inlet water tube support bracket. Remove intake manifold fasteners (9 bolts and one stud). Remove intake manifold.
7. To install, reverse removal procedure. Tighten all fasteners to specification. (Scheme 7) See TORQUE SPECIFICATIONS.

Scheme 5

Removal & Installation (Stratus & Breeze)

Remove exhaust pipe from manifold, it may be necessary to remove entire exhaust system. Remove exhaust manifold heat shield. Remove oxygen sensor (if necessary). Remove 8 exhaust manifold retaining bolts and remove manifold. (Scheme 8) To install, reverse removal procedure. See TORQUE SPECIFICATIONS.

Scheme 6

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-54166-S18221671892001011700000). Disconnect negative battery cable. Drain cooling system. Remove air cleaner inlet duct and air cleaner. Disconnect all vacuum lines, electrical wiring and fuel lines from throttle body.
2. Remove throttle linkage. Remove accessory drive belts. Remove power brake vacuum hose from intake manifold. Raise vehicle and remove exhaust pipe from manifold. Remove power steering pump assembly and set aside.
3. Disconnect coil pack wiring connector and remove coil pack and bracket from engine. Remove cylinder head cover. Remove cam sensor and fuel injectors wiring harness connectors.
4. Remove intake manifold. See «INTAKE MANIFOLD»(ref-54166-S10630628082001011700000). Carefully remove the timing belt. See «TIMING BELT»(ref-54166-S41200833482001011700000). Remove rocker arm shaft assemblies. Remove cylinder head bolts and remove cylinder head.
5. To install, reverse removal procedure. Clean and oil bolt threads before installation. Short bolts should be installed in positions No. 7, 8, 9 and 10. (Scheme 9) Tighten head bolts in sequence using 4-step torque/turn method. (Scheme 9) 1st: tighten to 25 ft. lbs. (34 N.m). 2nd: tighten to 50 ft. lbs. (68 N.m). 3rd: tighten to 50 ft. lbs. (68 N.m). 4th: tighten an additional 1/4 turn (DO NOT use a torque wrench for 4th step).

Scheme 7

Remove timing belt. See TIMING BELT . Using Sprocket Puller (6793) and Puller Insert (C4685), remove crankshaft sprocket. Using Seal Puller (6771), remove front oil seal. Ensure front cover remains undamaged.

Using Seal Installer (6780), install NEW seal until flush with cover. Using Sprocket Installer (6792), install crankshaft sprocket. To complete installation, reverse removal procedure.

1. Place cylinder No. 1 at TDC of compression stroke. Remove drive belts. Raise and support vehicle and remove right inner splash shield. Remove crankshaft damper bolt and using Puller (1026) and Insert (6827-A), remove damper.
2. Lower vehicle. Place jack under engine. Remove right engine mount and bracket. Remove timing belt cover fasteners and cover. Align timing marks as shown. see scheme 8 Loosen timing belt tensioner screws and remove timing belt.

Note. Neither camshaft nor crankshaft should be rotated after timing belt removal. Damage to valve components may occur. ALWAYS align timing marks before removing timing belt.

1. When tensioner is removed from engine it is necessary to compress the plunger into the tensioner body. Place tensioner into a vise equipped with soft jaws and slowly compress the plunger. Make sure to index tensioner in vise the same way it is installed on the engine. This is to ensure proper pin orientation when tensioner is installed on the engine.
2. When plunger is compressed into the tensioner body install a 5/64" (1.9 mm) Allen wrench or pin through body and plunger to retain plunger in place until tensioner is installed. Set crankshaft sprocket to TDC by aligning sprocket with arrow on oil pump housing then back off to 3 notches before TDC.
3. Set camshaft to TDC by aligning mark on sprocket with arrow on rear of timing belt cover. Move crankshaft to 1/2 mark before TDC for belt installation. see scheme 9 Install timing belt. Starting at crankshaft, go around water pump sprocket and then around camshaft sprocket.
4. Move crankshaft sprocket to TDC to take up belt slack. Install tensioner to block but do not tighten fasteners. Using a torque wrench on tensioner pulley, apply 250 INCH lbs. (28 N.m) of torque. see scheme 8 With torque being applied to the tensioner pulley move the tensioner up against tensioner pulley bracket and tighten fasteners. Pull tensioner plunger pin. Pretension is correct when pin can be removed and installed.
5. Rotate crankshaft 2 revolutions and check the alignment of timing marks. To complete installation, reverse removal procedure.

Scheme 8

Scheme 9

1. Remove cam cover. Mark rocker arm shaft assemblies for reassembly reference. Loosen rocker attaching bolts. Remove rocker arm shaft assemblies from cylinder head. Make marks that will help identify rocker arms spacers and retainers for reassembly reference.
2. Disassemble rocker arm assemblies by removing attaching bolts from shaft. Slide rocker arms and spacers from shaft. Keep spacers and rocker arms in same location relative to each other for reassembly reference.

Remove cam cover. Mark rocker arms for reassembly reference and remove. See ROCKER ARMS & VALVE LASH ADJUSTERS . Remove timing belt and camshaft sprocket. See TIMING BELT . Remove cylinder head. See CYLINDER HEAD. Remove camshaft sensor and remove camshaft from rear of cylinder head.

Lubricate bearing journals with clean oil and install camshaft. Install cam sensor and tighten bolts. Move cam as far back as it will go. Using a dial indicator, check end play. End play should be .005-.013" (.12-.33 mm). Install camshaft seal. Camshaft must be installed before seal is installed. Install camshaft sprocket. To complete installation, reverse removal procedure.

Remove engine from vehicle or transmission and flywheel from engine as necessary to gain access to seal. See ENGINE . Using a screwdriver, carefully pry rear seal out. DO NOT nick or damage crankshaft flange seal surface or retainer bore.

Place Magnetic Pilot (6926-1) on crankshaft. Position seal over pilot. Ensure words THIS SIDE OUT face out so they can be seen. Drive seal into the block using Drive (6926-2) and Handle (C-4171) until tool bottoms out. To complete installation, reverse removal procedure.

1. Drain cooling system to the thermostat level or below.
2. Remove coolant recovery ssytem (CRS) hose and thermostat/engine outlet connector bolts see scheme 12 and see scheme 13 2.0/2.4L Engines. 2.5L engine remove inlet hose and coolant elbow from theremostat housing see scheme 14
3. Remove thermostat assembly, and clean sealing surfaces.

Scheme 10

Scheme 11

1. Raise vehicle on hoist. Remove right inner splash shield. Remove accessory drive belts and power steering pump. Drain cooling system. Support engine from bottom and remove right engine support.
2. Remove power steering pump bracket bolts and set pump and bracket assembly aside. Note that the lines need not be disconnected.
3. Remove right engine mount bracket. Remove timing belt. See «TIMING BELT»(ref-54166-S41200833482001011700000) . Remove inner timing belt cover. Remove water pump-to-engine attaching screws. Remove water pump.

Install NEW "O" ring in water pump body "O" ring groove. Assemble pump body to block and tighten screws to 106 INCH lbs. (12 N.m). Pressurize cooling system to 15 psi (1.05 kg/cm 2 ) and check for leaks at pump shaft seal and "O" ring. Rotate pump by hand to ensure freedom of movement. To complete installation, reverse removal procedure.

1. Drain oil. Remove transmission bending bracket. Remove front engine mount and bracket. Remove transmission inspection cover. If equipped with A/C, remove oil filter and adapter. Remove oil pan.
2. To install, clean oil pan and engine gasket surfaces. Apply silicone rubber adhesive to engine block parting line. Install oil pan gasket to block. Install pan and tighten screws to 106 INCH lbs. (12 N.m).

Removal & Disassembly

1. Disconnect battery ground cable. Remove timing belt. See TIMING BELT under «REMOVAL & INSTALLATION»(ref-54166-S36192066702001011700000). Remove the oil pan. See OIL PAN under REMOVAL & INSTALLATION. Remove crankshaft sprocket. Remove oil pick-up tube. Remove oil pump bolts and oil pump.
2. Remove relief valve threaded plug, gasket, spring and valve. Remove oil pump cover screws and lift off cover. Remove pump rotors. see scheme 19 Wash all parts in solvent and inspect for wear or damage.

Reassembly & Installation

1. Using NEW parts as required, assemble pump. Note that the inner rotor should be installed with chamfer facing cast iron oil pump cover.
2. Install cover and tighten screws to 106 INCH lbs. (12 Nm). Install relief valve, spring, gasket and threaded plug. Tighten plug to 30 ft. lbs. (41 N.m).
3. Prime pump by filling rotor cavity with clean engine oil. Install "O" ring into counterbore on oil pump discharge passage. Apply Mopar Gasket Maker to oil pump mating surface.
4. Install oil pump slowly onto crankshaft until seated to engine block. Tighten bolts to 21 ft. lbs. (28 N.m). To complete installation, reverse removal procedure.