2.5L V6 Engine - VIN [H]: 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-54219-S40414158342001011700000) .
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-54219-S40414158342001011700000).
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 50) These are quick connect fittings. Refer to «Quick-Connect Fittings»(ref-54219-S29823871322010033100000).
10. Disconnect fuel supply line from the fuel brake module.
11. Remove fuel filter (Scheme 51)

Scheme 49

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-54219-S18547673102010033100000) .
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.

Note. Engine is removed with transaxle out bottom of vehicle.

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-54219-S40414158342001011700000) . Remove fuel line from fuel rail.
2. Disconnect and remove battery and tray. Set Powertrain Control Module (PCM) aside. Drain cooling system. Remove upper and lower radiator hoses and fan module.
3. Disconnect automatic transmission cooler line and plug (if equipped). Disconnect transmission shift linkage. Disconnect throttle body linkage. Disconnect engine wiring harness. Disconnect heater hoses.
4. Discharge A/C system using approved refrigerant recovery/recycling equipment. Raise vehicle and remove right inner splash shield. Remove accessory drive belts.
5. Remove axle shafts. See appropriate «FWD AXLE SHAFTS»(ref-43051) article in DRIVE AXLES section. Disconnect exhaust pipe from manifold. Remove front and rear engine mount brackets from body.
6. Lower vehicle. Remove air cleaner assembly. Remove power steering pump and reservoir and set aside. Remove A/C compressor. Remove ground straps to body. Raise vehicle. Install Engine Dolly (6135) and Cradle (6710) under engine.
7. Loosen cradle engine mounts to allow movement for positioning onto engine locating holes on engine cradle. Lower vehicle and position cradle mounts until engine is resting on mounts. Tighten mounts to cradle frame to keep mounts from moving while removing or installing engine/transmission.
8. Lower vehicle until ONLY weight of engine/transmission is on cradle. Remove engine and transmission mount bolts. Raise vehicle slowly. It may be necessary to move engine/transmission assembly on cradle to allow for removal around body flanges.

To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS . To fill and bleed cooling system, see COOLING SYSTEM BLEEDING . Adjust transmission linkage if necessary.

Scheme 50

Scheme 51

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-54219-S40414158342001011700000) . Disconnect fuel supply tube from rail. Disconnect MAP and intake air temperature sensor connectors.
2. Remove plenum support bracket bolt located to rear of MAP sensor. Remove bolt holding air inlet resonator to intake manifold. Loosen throttle body air inlet hose clamp.
3. Release snaps holding air cleaner cover and inlet hoses from engine. Disconnect TPS and idle air control motor connectors. Squeeze retainer tab on throttle cable and slide cable out of bracket. Slide cruise control cable out of bracket (if equipped).
4. Remove EGR tube from intake manifold. Remove plenum support bracket bolt, located to rear of EGR tube. Remove 7 bolts retaining upper intake plenum and remove plenum.
5. Disconnect electrical connectors from fuel injectors. Remove 4 bolts retaining fuel rail. Lift fuel rail off engine. Remove lower intake manifold attaching bolts and remove manifold.

To install, reverse removal procedure. Using NEW gaskets, install intake manifold. Tighten all bolts to specification and in correct sequence. See TORQUE SPECIFICATIONS. (Scheme 54)

Scheme 52

1. Raise vehicle. Disconnect exhaust pipe from rear manifold at flex joint (it may be necessary to remove entire exhaust system). Remove crossover pipe-to-manifold bolts and remove crossover assembly. Remove heat shield from rear exhaust manifold.
2. Remove power steering pump bracket. Remove nuts attaching rear manifold to cylinder head and remove manifold. Lower vehicle. Remove screws attaching front heat shield to manifold. Remove nuts attaching front manifold to cylinder head and remove manifold.

Using NEW gaskets, install manifolds and tighten to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

Remove camshaft sprockets. See TIMING BELT . Remove intake manifold. Refer to INTAKE MANIFOLD . Remove distributor. Remove exhaust manifold and crossover. See EXHAUST MANIFOLD . Remove water inlet pipe assembly, valve covers, ground strap, dipstick bracket, exhaust brackets, and alternator bolts. Remove cylinder head bolts. Remove cylinder head.

1. Before installing head bolts, clean and lube threads with engine oil. Install head gasket over locating dowels. Ensure gasket is installed on correct side. Install cylinder head over dowels.
2. Tighten cylinder head bolts to specification in correct sequence. See «TORQUE SPECIFICATIONS»(ref-54219-S19393984362001011700000). To complete installation, reverse removal procedure. (Scheme 55)

Scheme 53

Remove timing belt. See TIMING BELT . Carefully remove crankshaft sprocket and key using screwdriver tip covered with shop rag. Remove crankshaft seal using Seal Remover (C-4679A).

Install new crankshaft seal using Seal Installer (MD998717). Install crankshaft sprocket using Sprocket Installer (MD998713). To complete installation, reverse removal procedure.

1. Raise and support vehicle. Remove right inner splash cover. Remove accessory drive belts. Remove right engine support assembly vertical fasteners from frame rail. Lower vehicle. Support engine assembly with floor jack to remove load from engine mounts. Remove 3 bolts attaching engine support assembly to engine bracket. Remove right engine mount. Remove crankshaft damper. Remove right engine mount bracket. NOTE: To remove engine mount bracket, lower timing belt cover must first be removed.
2. Remove upper left timing belt cover. Remove lower timing belt cover. Remove upper right timing belt cover. Mark timing belt direction of rotation for installation reference. Loosen timing belt automatic tensioner bolts and remove timing belt. NOTE: To remove right/rear timing belt cover, power steering pump bracket must be removed.

1. Set crankshaft to TDC by aligning mark on sprocket with mark on oil pump housing, then back off 3 notches before TDC. (Scheme 56)
2. Set camshaft sprockets by aligning timing marks on sprockets with marks on rocker covers. (Scheme 57)
3. Install timing belt on rear camshaft sprocket first and install a binder clip to keep belt in position. Keeping belt taught, install belt underneath water pump pulley and then around front camshaft sprocket. Install another binder clip on front sprocket and belt.
4. Rotate crankshaft clockwise to TDC. see scheme 12 Continue routing belt by idler pulley and around crankshaft sprocket to tensioner pulley.
5. Apply rotating force to crankshaft sprocket, in clockwise direction, to tension belt. Ensure all timing marks are aligned.
6. Using Tensioner Wrench (MD998767) and a torque wrench, apply 39 INCH lbs. (4.4 N.m) to tensioner and tighten tensioner pulley bolt to specification. See «TORQUE SPECIFICATIONS»(ref-54219-S19393984362001011700000).
7. With torque being applied to tensioner pulley, install tensioner to tensioner pulley bracket and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-54219-S19393984362001011700000). Pull tensioner plunger locking pin.
8. Rotate crankshaft 2 revolutions clockwise, and check alignment of timing marks. Install tensioner pin into assembly. Pin should slide in and out with no resistance. If pin does not slide freely, repeat timing belt installation procedure. To complete installation, reverse removal procedure. Tighten all nuts and bolt to specification. See «TORQUE SPECIFICATIONS»(ref-54219-S19393984362001011700000).

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Remove intake manifold plenum. See INTAKE MANIFOLD. Remove valve covers. Identify rocker arm assembly and rocker arms before disassembly. see scheme 13 Install Auto Lash Adjuster Retainers (MD998443) to hold lash adjusters in position when rocker arms are removed. (Scheme 58) Remove rocker arm assembly bolts. Remove rocker arm assemblies.

Rotate camshaft until lobes are in a neutral position (little or no load to valves). Install rocker arm and shaft assembly with FLAT on shaft facing timing belt side of engine on right head and transmission on left side head. Install retainers and spring clips in original positions on exhaust and intake rocker shafts. Tighten bolts, in sequence shown. (Scheme 60) See TORQUE SPECIFICATIONS.

Scheme 58

1. Remove rocker arm assemblies. Refer to procedures under «ROCKER ARM & VALVE LASH ADJUSTER»(ref-54219-S00334840112001011700000) . Remove timing belt and camshaft sprockets. See «TIMING BELT»(ref-54219-S41959352522002031300000) . Remove cylinder heads. See «CYLINDER HEAD»(ref-54219-S32733871912001011700000) .
2. Remove thrust case from left head. Remove camshaft from rear of head. Remove distributor from right head. Remove camshaft from rear of head.

To install, reverse removal procedure.

Scheme 59

Remove engine. See ENGINE . Separate engine and transaxle. Remove oil pan. Remove rear seal housing. Pry out rear seal with screwdriver. DO NOT nick or scratch crankshaft flange seal surface or housing bore.

Using Seal Installer (MD998718), install oil seal into housing. Apply silicone rubber adhesive sealant to oil seal housing. Apply light coating of oil to seal lip. Install seal assembly on cylinder block and tighten bolts to 96 INCH lbs. (11 N.m). Reverse removal procedure.

1. Disconnect negative cable from auxiliary jumper terminal. Remove air inlet resonator.
2. Drain cooling system.
3. Remove upper radiator crossmember. CAUTION: Plastic tanks, while stronger then brass are subject to damage by impact, such as wrenches.
4. Remove hose clamps and hoses from the radiator.
5. Disconnect automatic transmission hoses from cooler and plug off.
6. Disconnect the fan wiring connector.
7. Disconnect the engine block heater wire (if equipped).
8. Remove the air conditioning condenser attaching screws located at the front of the radiator (if equipped). It is not necessary to discharge the air conditioning system to remove radiator.
9. Radiator can now be lifted free from engine compartment. Care should be taken not to damage radiator cooling fins or water tubes during removal.

1. Slide radiator and fan module down into position, seat the radiator assembly lower rubber isolators in the mount holes provided.
2. Attach air conditioning condenser to radiator (if equipped). See «TORQUE SPECIFICATIONS»(ref-54219-S19393984362001011700000) .
3. Connect engine block heater wire (if equipped).
4. Connect lower radiator hose and clamp. Connect automatic transmission hoses.
5. Connect fan motor electrical connection.
6. Install upper radiator hose. Align hose so it does not interfere with the accessory drive belt or engine. Position hose clamp so it will not interfere with the hood liner.
7. Install upper radiator crossmember.
8. Connect negative cable from auxiliary jumper terminal.
9. Fill cooling system with coolant.
10. Operate engine until it reaches normal operating temperature. Check cooling system and automatic transmission for correct fluid levels.

1. Drain cooling system to the thermostat level or below.
2. Remove coolant recovery system (CRS) hose and thermostat/engine outlet connector bolts see scheme 18 and see scheme 19 2.0/2.4L Engines. 2.5L engine remove inlet hose and coolant elbow from thermostat housing see scheme 20
3. Remove thermostat assembly, and clean sealing surfaces.

Scheme 60

Scheme 61

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 20

Drain cooling system. Remove timing belt if necessary. See TIMING BELT . Remove water pump mounting bolts. Separate water pump from water inlet pipe and remove.

Note. Water pump bolts directly to engine block. Pump cannot be rebuilt and must be serviced as a unit.

Clean all gasket and "O" ring surfaces. Install NEW "O" ring on water pipe (wet "O" ring with water to aid assembly). DO NOT allow oil or grease to contact "O" ring. Install NEW gasket on water pump and install pump inlet opening over water pipe. Install pump-to-block bolts and tighten to 20 ft. lbs. (27 N.m). To complete installation, reverse removal procedure.

Disconnect negative battery cable. Remove engine support module. Remove engine oil dipstick. Raise vehicle and drain engine oil. Remove starter. Remove engine to transaxle struts. Remove transaxle inspection cover. Remove oil pan bolts and remove oil pan.

Apply a 1/8" bead of silicone rubber adhesive sealant at parting line of oil pump body and rear seal retainer. To complete installation, reverse removal procedure. Tighten all bolts to specification. See TORQUE SPECIFICATIONS .

Removal & Disassembly

Remove accessory drive belts. Remove crankshaft dampener. Remove timing belt. See TIMING BELT under REMOVAL & INSTALLATION. Remove attaching bolts holding oil pump to block and remove pump. see scheme 26

Reassembly & Installation

1. Assemble pump, using new parts as required, with clean oil. Align marks on inner and outer rotors during assembly. Install and tighten screws. See «TORQUE SPECIFICATIONS»(ref-54219-S19393984362001011700000) . Install relief valve, spring, gasket and cap and tighten.
2. To install, reverse removal procedure. Prime cavity with oil before installation. Apply a .118" (3 mm) bead of gasket maker to oil pump perimeter prior. Install oil-ring into counter bore on oil pump body discharge passage. Install oil pump slowly onto crankshaft until seated to engine block and tighten. See «TORQUE SPECIFICATIONS»(ref-54219-S19393984362001011700000) .

Scheme 62

OIL PUMP SPECIFICATIONS