2.4L 4-CYL. Engine - VIN [X]: Removal & Installation Dodge Stratus I

REMOVAL & INSTALLATION

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also 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-54187-S24469138752001011700000) .
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-54187-S24469138752001011700000).
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 19) These are quick connect fittings. Refer to «Quick-Connect Fittings»(ref-54187-S34487903122010033100000).
10. Disconnect fuel supply line from the fuel brake module.
11. Remove fuel filter (Scheme 20)

Scheme 18

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 LINES AND QUICK CONNECT FITTINGS»(ref-54187-S01430564012010033100000) .
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.

Removal & Installation (1996)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-54187-S24469138752001011700000) . Disconnect and remove battery and tray. Set Power Control Module (PCM) aside. Drain cooling system. Remove upper radiator hose and remove radiator fan module. Remove lower radiator hose. Disconnect A/T cooler lines and plug, if equipped.
2. Disconnect transmission shift linkage. Disconnect throttle body linkage. Disconnect engine wiring harness. Disconnect heater hoses. Discharge A/C system using approved refrigerant recovery/recycling equipment.
3. Raise and support vehicle. Remove right inner splash shield. Remove accessory drive belts. Remove axle shafts. See «FWD AXLE SHAFTS»(ref-43051) article in DRIVE AXLES. Disconnect exhaust pipe from manifold. Remove front and rear engine mount brackets from body. Lower vehicle.
4. Remove air cleaner assembly. Remove P/S pump and reservoir and set aside. Remove A/C compressor. Remove ground straps to body. Raise vehicle to allow Dolly and Cradle (6135 and 6710) to be installed under vehicle. Loosen cradle engine mounts to allow movement for positioning into engine locating holes on engine bedplate. Lower vehicle and position cradle mounts until engine is resting on mounts. Tighten cradle frame mounts to prevent movement when removing or installing engine and transmission.
5. Lower vehicle until ONLY the weight of engine and transmission is on the cradle. Remove engine and transmission mount bolts. Raise vehicle slowly. It may be necessary to move engine/transmission assembly on cradle to allow passage past body flanges. To install, reverse removal procedure. Add fluids. Adjust transmission linkage.

Removal & Installation (1997)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-54187-S24469138752001011700000) . Disconnect and remove battery. Remove air cleaner assembly. Drain cooling system. Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect A/T cooler line and plug, if equipped. Remove cooling module assembly. Disconnect transmission shift linkage.
2. Disconnect throttle body linkage. Disconnect engine and transmission wiring harness. Raise and support vehicle.
3. Remove right inner splash shield. Remove battery splash shield. Drain engine oil. Remove accessory drive belts. Remove axle shafts. See «FWD AXLE SHAFTS»(ref-43051) article in DRIVE AXLES. Disconnect exhaust pipe from manifold. Remove engine support module. Remove front and rear engine mount brackets from engine and transmission. Remove engine/transmission brace. Remove flex plate cover. Remove converter bolts and mark converter for assembly. Lower vehicle.
4. Remove P/S pump and reservoir and set aside. Remove suction line from A/C compressor. Cap ports. Remove ground straps to body. Raise vehicle to allow Dolly and Cradle (6135 and 6710) to be installed under vehicle. Loosen cradle engine mounts to allow movement for positioning into engine locating holes on engine bedplate. Lower vehicle and position cradle mounts until engine is resting on mounts. Tighten cradle frame mounts to prevent movement when removing or installing engine and transmission.
5. Lower vehicle until ONLY the weight of engine and transmission is on the cradle. Remove engine and transmission mount bolts. Raise vehicle slowly. It may be necessary to move engine/transmission assembly on cradle to allow passage past body flanges. To install, reverse removal procedure. Fill fluids. Adjust transmission linkage.

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-54187-S24469138752001011700000). Disconnect negative battery cable from strut tower. Remove air intake resonator. Disconnect fuel supply line quick-connect at fuel tube assembly. Remove fuel rail assembly attaching screws and remove fuel rail from engine. Cover injector holes to prevent entry of foreign material.
2. Remove accelerator, kickdown and speed control cables from throttle lever and bracket. Disconnect Idle Air Control (IAC) motor and Throttle Position (TP) sensor wiring connectors. Disconnect vacuum hoses from throttle body. Disconnect Manifold Absolute Pressure (MAP) sensor, Inlet Air Temperature (IAT) sensor, and Knock Sensor (KS) connectors. Disconnect vapor and brake booster hoses and wiring harness from tab located on intake manifold.
3. Remove transmission-to-throttle body support bracket fasteners at throttle body and loosen fastener at transmission end. Remove EGR tube bolts at valve and at intake manifold. Remove tube from engine. Remove intake manifold-to-engine support bracket. Remove 10 intake manifold bolt and washer assemblies. Remove intake manifold.
4. To install, reverse removal procedure. Use NEW gaskets and tighten all fasteners to specification. (Scheme 21)or (Scheme 22). See «TORQUE SPECIFICATIONS»(ref-54187-S16321556062001011700000).

Scheme 19

Scheme 20

Remove exhaust pipe from manifold, (it may be necessary to remove entire exhaust system). Remove exhaust manifold heat shield. Remove O2 sensor. Remove 8 exhaust manifold bolts and remove manifold. To install, reverse removal procedure. Tighten bolts from center outward. (Scheme 23) See TORQUE SPECIFICATIONS.

Scheme 21

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-54187-S24469138752001011700000) . Disconnect negative battery cable. Drain cooling system. Remove air cleaner and disconnect all vacuum lines, electrical wiring and fuel lines from throttle body. Remove throttle linkage. Remove accessory drive belts. Remove power brake vacuum hose from intake manifold.
2. Raise and support vehicle. Remove exhaust pipe from manifold. Remove P/S pump assembly and lay aside. Disconnect coil pack wiring connector and remove coil pack and bracket from engine. Remove wiring connectors for cam sensor and fuel injectors. Remove timing belt and camshaft sprockets. See «TIMING BELT»(ref-54187-S17601439552001011700000) . Remove idler pulley. Remove rear timing belt cover. Remove camshaft cover. Remove camshaft and followers. Remove cylinder head bolts. Remove cylinder head.

To install, reverse removal procedure. Clean and oil bolt threads before installation. Tighten head bolts in sequence using 4-step torque turn method. (Scheme 24)

1. 1st: Tighten to 25 Ft. Lbs. (34 N.m).
2. 2nd: Tighten to 50 Ft. Lbs. (68 N.m).
3. 3rd: (Repeat Step 2) Tighten to 50 Ft. Lbs. (68 N.m).
4. 4th: Tighten an additional 1/4 turn. (DO NOT use a torque wrench for 4th step).

Scheme 22

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.

Removal (Hydraulic Tensioner)

1. Remove No. 1 spark plug. Set cylinder No. 1 at TDC on compression stroke. Remove upper timing belt cover. Check timing marks on camshaft sprockets. (Scheme 26)
2. Raise and support vehicle. Remove right splash shield. Remove accessory belts. Remove crankshaft damper bolt. Using 3-jaw puller, remove damper. Remove engine mount bracket. Remove timing cover bolts and remove cover. Ensure timing marks are aligned. Lower vehicle. Loosen timing belt tensioner screws and remove timing belt.

Scheme 23

1. Remove No. 1 spark plug. Set No. 1 cylinder at TDC on compression stroke. Remove upper timing belt cover. Check timing marks on camshaft sprockets. (Scheme 26)
2. Raise and support vehicle. Remove right splash shield. Remove accessory belts. Remove crankshaft damper bolt. Using 3-jaw puller, remove damper. Remove engine mount bracket. Remove timing cover bolts and remove cover. Ensure timing marks are aligned. Lower vehicle.
3. Install 6-mm Allen wrench in tensioner pulley. (Scheme 25) Using Allen wrench, rotate tensioner pulley counterclockwise slightly. Insert a 1/8" or 3-mm Allen wrench in pinhole on front of tensioner pulley to lock in place. Remove timing belt.

Installation (Hydraulic Tensioner)

1. Place tensioner in vise and slowly compress plunger. With plunger compressed into tensioner body, install a pin through body and plunger to retain plunger in body until tensioner is installed. CAUTION: DO NOT attempt to compress tensioner plunger with tensioner assembly installed on engine. Damage to tensioner and other components will occur. Tensioner MUST be compressed using a vise. Index tensioner in vise the same as installed on engine. This ensures proper pin orientation when tensioner is installed on engine.
2. Set crankshaft sprocket to TDC. (Scheme 27) Set camshaft timing marks. (Scheme 26) Install timing belt, starting at crankshaft, go around water pump sprocket, idler pulley, camshaft sprockets and then around tensioner pulley. Install tensioner to block but DO NOT tighten bolts.
3. Using torque wrench on tensioner pulley, apply 21 ft. lbs. (28 N.m) to tensioner. (Scheme 28) With torque applied, move tensioner up against timing belt and tighten tensioner mounting bolts. Pull tensioner pin. Pre-tension is correct when pin can be removed and installed freely. Rotate crankshaft 2 revolutions and check alignment of timing marks. Recheck tensioner pin installation. To complete installation, reverse removal procedure.

Note. If pretension is incorrect and pin is removed, it may be necessary to remove timing belt tensioner to reinstall pin.

Scheme 24

Scheme 25

Scheme 26

Installation (Mechanical Tensioner)

Note. If timing belt is damaged due to alignment problems, replace tensioner assembly and idler pulley. On 1996 models, see technical service bulletin 09-11-96 Rev. A, dated 11/29/1996. See TENSIONER ASSEMBLY (MECHANICAL TENSIONER) .

1. Set crankshaft sprocket to TDC. see scheme 14 Set camshaft timing marks with exhaust camshaft sprocket mark one half tooth below intake camshaft sprocket mark. (Scheme 29) Ensure arrows are up.
2. Install timing belt, starting at crankshaft, go around water pump sprocket, idler pulley, camshaft sprockets and then around tensioner pulley. Move exhaust camshaft to tighten up slack and align marks. Remove Allen wrench from tensioner pulley (or pin from new tensioner). Rotate crankshaft 2 revolutions and check alignment of timing marks. To complete installation, reverse removal procedure. Assemble with engine mount installed, but top timing belt cover off. Start engine for a few seconds. Turn ignition off. Measure distance between outer edge of timing belt and edge of intake camshaft sprocket. Belt should 0.08-0.24" (2-6 mm) from edge of sprocket. NOTE: Procedure revised. On 1996 models, see technical service bulletin 09-11-96 Rev. A, dated 11/29/1996.

Scheme 27

Scheme 28

1. Remove camshaft cover. See CAMSHAFT. Remove timing belt, sprockets and covers. See «TIMING BELT»(ref-54187-S17601439552001011700000) . Remove camshaft(s). See CAMSHAFT. Remove camshaft follower assemblies from cylinder head. Keep camshaft followers and lash adjusters in order of removal for reassembly. Inspect followers for wear or damage. Replace as necessary. Lash adjusters are serviced as an assembly and cannot be rebuilt.
2. To install, reverse removal procedure. Lubricate camshaft follower and lash adjuster with clean oil. When installing lash adjusters, ensure they are at least partially full of oil. This is indicated by little or no plunger travel when adjuster is depressed.

Remove ignition coil pack. Remove camshaft cover bolts. Remove camshaft cover and ground strap. Remove timing belt, sprockets and covers. See TIMING BELT. Remove camshaft bearing caps in sequence, one camshaft at a time. Remove outside bearing caps first. (Scheme 31) Camshafts are not interchangeable. Identify for installation.

Note. To avoid damage, ensure pistons are not at TDC when installing camshafts.

1. Lubricate bearing journal and camshaft followers with clean oil and install camshafts. Install right and left camshaft bearing caps No. 2-5 and right cap No. 6. Tighten 6 mm bearing cap bolts to 106 INCH lbs. (12 N.m) in sequence. (Scheme 32)
2. Apply Mopar Gasket Maker to bearing caps No. 1 and 6. (Scheme 33) Install bearing caps and tighten 8 mm bolts to 21 ft. lbs. (28 N.m). Bearing caps must be installed before seals can be installed. To complete installation, reverse removal procedure.

Scheme 29

Scheme 30

Scheme 31

1. Remove timing belt. See «TIMING BELT»(ref-54187-S17601439552001011700000) . Remove oil pump. See «OIL PUMP»(ref-54187-S38205601892001011700000) under ENGINE OILING. Remove rear timing belt cover. Remove oil pan. Remove balance shaft chain cover, chain guide and tensioner. Remove balance shaft gear and chain sprocket retaining screws. Using wide pry bars, remove chain and sprocket assembly.
2. Remove front balance shaft cover and balance shaft gears. Remove rear balance shaft cover and balance shafts. Remove 4 carrier-to-crankcase bolts and separate balance shaft carrier from engine. Check bearing surfaces and gears for scuffing and wear. Replace as necessary.

1. To install, reverse removal procedure. Ensure crankshaft to balance shaft timing is established. With balance shafts installed in carrier, position carrier on crankcase and install 4 attaching bolts. Tighten attaching bolts to 40 ft. lbs. (54 N.m).
2. Turn balance shafts until both shaft keyways are up. Install short hub (drive) gear on right hand balance shaft. Install long hub (driven) gear on left hand balance shaft. Ensure keyways are up and gear alignment dots are meshed after installation. (Scheme 34)
3. Install gear cover and tighten double ended stud/washer to 105 INCH lbs. (12 N.m). Using Installer (6052), install crankshaft sprocket. Turn crankshaft until No. 1 cylinder is at TDC. Timing marks on chain sprocket should align with parting line on left side of No. 1 main bearing cap. (Scheme 35)
4. Place chain over crankshaft sprocket so nickel plated link of chain is over No. 1 cylinder timing mark on crankshaft sprocket. (Scheme 35) Place balance shaft sprocket into timing chain so timing mark (Yellow dot) mates with lower nickel plated link on chain. (Scheme 36)
5. With balance shaft keyways pointed at 12 o'clock, slide balance shaft sprocket onto nose of balance shaft. Balance shaft may need to be pushed in slightly to provide clearance. NOTE: Timing mark on sprocket, lower nickel plated link, and arrow on side of gear cover should align when balance shafts are timed correctly.
6. If sprockets are correctly timed, install balance shaft bolts and tighten to 21 ft. lbs. (28 N.m). Place a wood block between crankcase and crankshaft counterbalance to prevent crankshaft and gear rotation.
7. Install chain tensioner loosely. Position guide on double-ended stud, ensuring tab on guide fits into slot on gear cover. Install and tighten nut/washer assembly to 106 INCH lbs. (12 N.m).
8. Place a shim.039" (1 mm) thick by 2.75" (70 mm) long between tensioner and chain. (Scheme 37) Apply firm pressure (5.5-6.6 lbs) against tensioner directly behind adjustment slot. With load applied, tighten top tensioner bolt first then bottom bolt to 106 INCH lbs. (12 N.m). Remove shim stock. Install balance shaft carrier covers and tighten screws to 106 INCH lbs. (12 N.m). To complete installation, reverse removal procedure.

Scheme 32

Scheme 33

Scheme 34

Scheme 35

1. Remove engine from vehicle. See «ENGINE»(ref-54187-S38491237462001011700000). Remove transaxle from engine. Remove clutch and drive plate from crankshaft. Remove transaxle upper cover. Using a screwdriver, carefully pry rear seal out. DO NOT nick or damage crankshaft flange seal surface or retainer bore.
2. Polish shaft seal lip surface with 400 grit paper, if necessary, to eliminate varnish, dirt or nicks. Put pilot (6926-1) on end of crankshaft. (Scheme 38) Place seal on tool. Using installer (6926-2) and handle (C-4171), lightly tap NEW seal into place until seal is flush with cylinder block surface. To install, reverse removal procedure.

Scheme 36

1. Drain cooling system to the thermostat level or below.
2. Remove coolant recovery system (CRS) hose and thermostat/engine outlet connector bolts (Scheme 39) and see scheme 26 2.0/2.4L Engines. 2.5L engine remove inlet hose and coolant elbow from thermostat housing see scheme 27
3. Remove thermostat assembly, and clean sealing surfaces.

Scheme 37

Scheme 38

1. Place the new thermostat assembly into the engine outlet connector. Align air bleed with notch on the cylinder head.
2. Install engine outlet connector onto cylinder head and tighten bolts to 12.5 N.m (110 in. lbs.). Connect the coolant recovery system (CRS) hose.
3. Fill cooling system. Refer to refilling System outlined in this section.

Installation - 2.5L Engine

Install thermostat into the recess in the thermostat housing. Install inlet elbow and tighten the bolts to 12 N.m (133 in. lbs.) see scheme 27

1. Raise vehicle on hoist. Remove right inner splash shield. Remove accessory drive belts and P/S pump. Drain cooling system. Support engine from bottom and remove right engine support. Remove P/S pump bracket bolts and set pump and bracket assembly aside (P/S lines need not be disconnected).
2. Remove right engine mount bracket. Remove timing belt. See «TIMING BELT»(ref-54187-S17601439552001011700000) . 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 to 106 INCH lbs. (12 N.m). Pressurize cooling system to 15 psi (1.05 kg/cm 2 ) and check pump shaft seal and "O" ring for leaks. Rotate pump by hand to ensure freedom of movement. To complete installation, reverse removal procedure.

Drain oil and remove oil pan. Clean oil pan and engine gasket surfaces. Apply silicone rubber adhesive to engine block parting line. see scheme 28 Install oil pan gasket to block. Install pan and tighten bolts to 106 INCH lbs. (12 N.m).

Drain oil. Remove engine support module. Remove collar from oil pan and transmission. Remove oil pan. Clean oil pan and engine gasket surfaces. Apply silicone rubber adhesive to engine block parting line. see scheme 28 Install oil pan gasket to block. Install pan and tighten bolts to 106 INCH lbs. (12 N.m). To complete installation, reverse removal procedure.

Scheme 39

Removal & Disassembly

1. Remove timing belt. See «TIMING BELT»(ref-54187-S17601439552001011700000) under REMOVAL & INSTALLATION. Remove oil pan. See OIL PAN under «REMOVAL & INSTALLATION»(ref-54187-S11782351472001011700000). Using Sprocket Puller (6793) and Puller Insert (C4685), remove crankshaft sprocket. Using Seal Puller (6771), remove front oil seal. Ensure front cover remains undamaged. Remove oil pump bolts and oil pump.
2. Remove relief valve threaded plug, gasket, spring and valve. see scheme 32 Remove oil pump cover screws and lift off cover.
3. Remove pump rotors. Wash all parts in solvent and inspect for wear or damage. See «OIL PUMP SPECIFICATIONS»(ref-54187-S09237176522001011700000) table.

Scheme 40

OIL PUMP SPECIFICATIONS

Note. Install inner rotor with chamfer facing cast iron oil pump cover.

Reassembly & Installation

1. Using NEW parts as required, assemble pump. Install cover and tighten screws to 106 INCH lbs. (12 N.m). Install relief valve, spring, gasket and threaded plug. see scheme 32 Tighten plug to 30 ft. lbs. (41 N.m).
2. 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.
3. Install oil pump slowly onto crankshaft until seated to engine block. Tighten bolts to 17 ft. lbs. (23 N.m). Install front seal after pump is installed. To complete installation, reverse removal procedure.