drain bolt CHRYSLER VOYAGER 1996 User Guide

INSTALLATIONÐ2.4L ENGINE
(1) Place a new gasket (dipped in clean water) on
the engine outlet connector surface. Center the ther-
mostat in thermostat housing (Fig. 25).
(2) Place the engine outlet connector and gasket
over the thermostat, making sure thermostat is
seated in the thermostat housing.
(3) Bolt outlet connector to thermostat housing
(Fig. 25). Tighten bolts to 28 N´m (250 in. lbs.).
(4) Refill the cooling system to the proper level.
Refer to Cooling System Refilling outlined in this sec-
tion for procedure
THERMOSTATÐ3.0L ENGINE
REMOVAL
(1) Drain cooling system down below the thermo-
stat level. Refer to Draining Cooling System in this
group.
(2) Remove thermostat housing bolts and housing
(Fig. 26).
(3) Remove thermostat, discard gasket and clean
both gasket sealing surfaces.
INSTALLATIONÐ3.0L ENGINE
(1) Center thermostat in water box pocket. Check
that the flange is seated correctly in the countersunk
portion of the intake manifold water box (Fig. 26)
and (Fig. 27).
(2) Install new gasket on water box.
(3) Install housing over gasket and thermostat
and tighten bolts to 12 N´m (105 in. lbs.).(4) Refill the cooling system to the proper level.
Refer to Cooling System Refilling outlined in this sec-
tion for procedure.
THERMOSTATÐ3.3/3.8L ENGINES
REMOVAL
(1) Drain cooling system down below the thermo-
stat level. Refer to Cooling System Draining in this
section.
(2) Remove thermostat housing bolts and housing
(Fig. 28).
(3) Remove thermostat, discard gasket and clean
both gasket sealing surfaces.
Fig. 26 Thermostat, Housing, and Water BoxÐ3.0L
Engine
Fig. 27 Thermostat InstalledÐ3.0L Engine
Fig. 28 Thermostat, Housing, and Water BoxÐ3.3/
3.8L Engines
7 - 20 COOLING SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Place a new gasket (dipped in water) on the
thermostat housing surface, center thermostat into
opening in the intake manifold water box.
(2) Place housing and gasket over the thermostat,
making sure thermostat is in the recess provided
(Fig. 28).
(3) Bolt housing to intake manifold, tighten bolts
to 28 N´m (250 in. lbs.).
(4) Refill the cooling system to the proper level.
Refer to Cooling System Refilling outlined in this sec-
tion for procedure.
RADIATOR
REMOVAL
(1) Disconnect negative cable from battery.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK PLUG OR THE RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
(2) Drain cooling system. Refer to Draining Cool-
ing System of this section.
(3) Remove air intake resonator.
(4) Remove coolant reserve system tank to filler
neck tube hose.
(5) Disconnect fans from the connector located on
the left side of the fan module.
(6) Remove the Coolant Recovery System (CRS)
tank retaining screw from the upper radiator closure
panel crossmember.
(7) Disconnect the upper radiator mounting
screws from the crossmember. Disconnect the engine
block heater wire if equipped.
(8) Remove the upper radiator closure panel
crossmember. Refer to Group 23 Body for procedure.
(9) Remove air cleaner assembly.
(10) Disconnect automatic transmission oil cooler
lines at radiator and plug.
(11) Disconnect inlet and outlet hoses from the
radiator. Remove the lower hose clip from the fan
module.
(12) Remove A/C condenser fasteners and sepa-
rate the condenser from the radiator (Fig. 29). Verify
the condenser is supported in position.
(13) Remove A/C filter/dryer mounting bracket, 2
bolts to the fan module, and 2 nuts to the filter/dryer.
(14) Radiator can now be lifted free from engine
compartment.Care should be taken not to dam-
age radiator cooling fins or water tubes during
removal.INSTALLATION
(1)Be sure the air seals are in position before
radiator is installed.Slide radiator down into posi-
tion behind closure panel. Seat the radiator with the
rubber isolators into the mounting holes provided,
with a 10 lbs. force.
(2) Install A/C filter/dryer and mounting bracket
onto fan module.
(3) Install Air Conditioning Condenser onto the
radiator (Fig. 29).
(4) Unplug and connect automatic transmission
oil cooler lines to radiator.
(5) Install inlet and outlet radiator hoses (includ-
ing coolant reserve hose) and connect the fan motor
electrical connection.
(6) Install air cleaner assembly.
(7) Install the upper radiator closure panel cross-
member. Refer to Group 23 Body for procedure.
(8) Install the upper radiator mounting screws.
Tighten radiator mounting bolts to 12 N´m (105 in.
lbs.). Connect the engine block heater wire if
equipped.
(9) Install the Coolant Recovery System (CRS)
tank retaining screw to the upper radiator closure
panel crossmember.
(10) Install air intake resonator.
(11) Fill cooling system. Refer to Cooling System
Filling in this section.
(12) Connect negative cable to battery.
RADIATOR DRAINCOCK
REMOVAL
CAUTION: Use of pliers on draincock is not rec-
ommended. Damage may occur to part. Draincock
should not be removed unless leakage observed.
(1) Turn the draincock stem counterclockwise to
unscrew the stem. When the stem is unscrewed to
Fig. 29 Air Conditioning Condenser Mounting
Fasteners
NSCOOLING SYSTEM 7 - 21
REMOVAL AND INSTALLATION (Continued)

the end of the threads turn back 1/8 turn and, pull
the stem (Fig. 30) from the radiator tank.
INSTALLATION
(1) Push the draincock assembly body into the
tank opening until it snaps into place.
(2) Tighten the draincock stem by turning clock-
wise until it stops.
FAN MODULE
REMOVAL
There are no repairs to be made to the fan or
shroud assembly. If the fan is warped, cracked, or
otherwise damaged, it must be replaced as a assem-
bly (Fig. 31).
(1) Raise the vehicle on hoist.
(2) Remove the radiator outlet hose from hose
retaining clip and remove clip from shroud.
(3) Remove lower auxiliary transmission cooler
lines from retaining clips on the fan module shroud,
if equipped.
(4) Lower the vehicle. Remove the air intake res-
onator from the throttle body and air cleaner assem-
bly.
(5) Disconnect the fans electrical connector
located on the left side of the fan module.
(6) Remove the Coolant Recovery System (CRS)
attaching screw from the upper crossmember.
(7) Remove upper grill to crossmember valence
panel.
(8) Disconnect the upper radiator mounts from the
crossmember. Remove the upper crossmember. Refer
to Group 23 Body for procedure.
(9) Remove the air cleaner assembly.
(10) Remove fan module retaining fasteners (Fig.
31).
(11) Remove upper auxiliary transmission cooler
lines from retaining clips on the fan module shroud,
if equipped.(12) Disconnect and plug the transmission line
from the radiator fitting on the lower left side.
(13) Raise vehicle on the hoist and remove the fil-
ter/drier, fan module and radiator mounting bolts
located on the lower right of the module.
(14) Lower the vehicle on hoist and remove the
upper fan module to radiator retaining clips.
(15) Remove the fan module from the vehicle.
INSTALLATION
(1) Install fan module assembly into attaching
clips on the radiator.
(2) Install the upper fan module to radiator
retaining clips.
(3) Raise vehicle on the hoist and install the fil-
ter/drier, fan module and radiator mounting fasten-
ers located on the lower right of the module.
(4) Lower the vehicle. Connect the transmission
line to the radiator fitting on the lower left side.
(5) Install the upper auxiliary transmission cooler
lines to the retaining clips on the fan module shroud,
if equipped.
(6) Install fan module retaining fasteners (Fig.
31). Tighten to 12 N´m (105 in. lbs.).
(7) Install the air cleaner assembly.
(8) Install the crossmember. Refer to Group 23
Body for procedure. Connect the upper radiator
mounts to the crossmember. Tighten fasteners to 12
N´m (105 in. lbs.).
(9) Install the Coolant Recovery System (CRS)
attaching screw to the upper crossmember. Tighten
to 2 N´m (18 in. lbs.).
(10) Install upper grill to crossmember valence
panel.
(11) Connect the fans to the connector located on
the left side of the fan module.
(12) Install the air intake resonator to the throttle
body and air cleaner assembly.
Fig. 30 Draincock Disassembled
Fig. 31 Fan Module
7 - 22 COOLING SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

(13) Raise the vehicle. Install the lower auxiliary
transmission cooler lines to the retaining clips on the
fan module shroud, if equipped.
(14) Install outlet hose retainer clip to the shroud.
Install the radiator outlet hose to the retaining clip.
(15) Lower the vehicle.
ENGINE BLOCK HEATER
REMOVAL
(1) Drain coolant from radiator and cylinder block.
Refer to Cooling System Drain, Clean, Flush and
Refill of this section for procedure.
(2) Remove power cord plug from heater.
(3) Loosen screw in center of heater. Remove
heater assembly.
INSTALLATION
(1) Thoroughly clean core hole and heater seat.
(2) Insert heater assembly with element loop posi-
tionedupward.
(3) With heater seated, tighten center screw
securely to assure a positive seal.
(4) Fill cooling system with coolant to the proper
level, vent air, and inspect for leaks. Pressurize sys-
tem with Radiator Pressure Tool before looking for
leaks.
(5) Install power cord plug to heater.
ACCESSORY DRIVE BELTSÐ2.4L
REMOVAL/INSTALLATION-ADJUST
GENERATOR AND AIR CONDITIONING
(1) Loosen lower generator pivot bolt and upper
locking nut, then loosen adjusting bolt (Fig. 32) to
remove belt tension.
CAUTION: Belt damage may occur if the following
procedure is not performed.
(2) Tighten lock nut to 21 N´m (180 in. lbs.) and
torque generator pivot bolt to 54 N´m (40 ft. lbs.). To
assure proper alignment of generator assembly.
Adjust belt tension by tightening the adjusting bolt
until proper belt tension is obtained. Refer to tension
specification in Belt Tension Chart.
(3) Torque lock nut to 54 N´m (40 ft. lbs.).
POWER STEERING PUMP
(1) From on top of the vehicle loosen locking nuts
D and F (Fig. 33).
(2) From under the vehicle loosen the pivot bolt E.
Loosen adjusting bolt G until belt can be removed.
(3) After installing a new belt, adjust belt tension
by tightening the adjusting bolt until the proper ten-sion obtained. Refer to tension specification in Belt
Tension Chart.
(4) Tighten locking nuts D and F to 54 N´m (40 ft.
lbs.).
(5) Tighten pivot bolt E to 54 N´m (40 ft. lbs.)
Fig. 32 Air Conditioning Compressor/Generator
BeltsÐ2.4L
Fig. 33 Power Steering Pump Adjustment
NSCOOLING SYSTEM 7 - 23
REMOVAL AND INSTALLATION (Continued)

(3) Remove power steering pump bracket bolts and
set pump and bracket assembly aside. Power steering
lines do not need to be disconnected.
(4) Remove timing belt.
(5) Remove inner timing belt cover.
(6) Remove water pump attaching screws to engine
(Fig. 15).
INSTALLATION
(1) Install new O-ring gasket in water pump body
O-ring groove (Fig. 16). Use small dabs of Mopar Sil-
icone Rubber Adhesive Sealant around the water
pump body to secure O-ring in place during installa-
tion.
CAUTION: Make sure O-ring gasket is properly
seated in water pump groove before tightening
screws. An improperly located O-ring may cause
damage to the O-ring and cause a coolant leak.
(2) Assemble pump body to block and tighten
screws to 12 N´m (105 in. lbs.). Pressurize cooling
system to 15 psi with pressure tester and check
water pump shaft seal and O-ring for leaks.
(3) Rotate pump by hand to check for freedom of
movement.
(4) Install inner timing belt cover.
(5) Install timing belt.
(6) Fill cooling system. SeeFilling Cooling Sys-
tem.
(7) Install power steering pump and accessory
drive belts.
WATER PUMP Ð 2.5L VM DIESEL
REMOVAL
(1) Drain cooling system. Refer to Draining Cool-
ing System in this Group.
(2) Remove the right inner splash shield (Fig. 17).
(3) Loosen the water pump pulley attaching bolts
(Fig. 18) before the accessory drive belt is removed.
(4) Loosen water pump accessory drive belts (Fig.
19). Remove water pump pulley.(5) Remove water pump attaching bolts and
remove pump.
INSTALLATION
(1) Install a new water pump to housing O-ring
gasket. Install pump and tighten the attaching bolts
to 22.6 N´m (205 in. lbs.)
Fig. 15 Water Pump Ð 2.0L Gasoline
Fig. 16 Water Pump Body Ð 2.0L Gasoline
Fig. 17 Right Side Splash Shield
Fig. 18 Water Pump and Pulley Ð 2.5 L VM Diesel
7 - 8 COOLING SYSTEMNS/GS
REMOVAL AND INSTALLATION (Continued)

(2) Install water pump pulley.
(3) Install drive belt, Refer to Accessory Drive
Belts, this Group. Tighten water pump pulley attach-
ing bolts to 27.5 N´m (240 in. lbs.)
(4) Install right inner splash shield.
(5) Refill cooling system. Refer to Refilling Cooling
System in this Group.
ENGINE THERMOSTATÐ 2.0L GASOLINE
REMOVAL
(1) Drain cooling system to the thermostat level or
below.
(2) Remove coolant recovery system (CRS) hose
and thermostat/engine outlet connector bolts.
(3) Remove thermostat and seal, and clean sealing
surfaces.
INSTALLATION
(1) Place the new thermostat assembly into the
thermostat housing/outlet connector. Align air bleed
vent with notch in cylinder head.
(2) Install thermostat housing/outlet connector
onto cylinder head and tighten bolts to 12.5 N´m (110
in. lbs.). Connect the upper radiator hose.
(3) Refill cooling system (seeRefilling System).
THERMOSTAT Ð 2.5L VM DIESEL
REMOVAL
(1) Drain cooling system down below the thermo-
stat level. Refer to Draining Cooling System in this
section.(2) Remove radiator hose at thermostat cover.
(3) Remove thermostat cover bolts (Fig. 20).
(4) Remove Thermostat.
INSTALLATION
(1) Remove old gasket material from thermostat
housing and cover.
(2) Install new thermostat gasket.
(3) Install thermostat and tighten cover bolts to
10.8 N´m (96 in. lbs.).
(4) Install radiator hose.
(5) Refill cooling system. Refer to Refilling Cooling
System in this section.
RADIATOR Ð 2.5L VM DIESEL
REMOVAL
(1) Disconnect battery.
(2) Remove power steering reservoir attaching
bolts, and reposition reservoir.
(3) Remove radiator closure panel crossmember
(Fig. 21).
(4) Remove air cleaner housing and intake hose.
(5) Unplug fan module 4 pin wiring connector.
(6) Drain cooling system. Refer to Draining cooling
system in this section for procedure.
(7) Remove upper and lower Radiator Hoses.
(8) Remove radiator attaching bolts.
(9) Loosen A/C receiver/dryer lower bolt.
(10) Remove Radiator.
(11) Remove fan module from radiator.
Fig. 19 Water Pump Drive BeltÐ 2.5 L VM Diesel
Fig. 20 Thermostat and Housing Ð 2.5L VM Diesel
NS/GSCOOLING SYSTEM 7 - 9
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Reverse the above procedure for installation.
ENGINE COOLANT TEMPERATURE SENSORÐ3.0L
The sensor is installed next to the thermostat
housing (Fig. 3).
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
REFER TO GROUP 7- COOLING.
REMOVAL
(1) With the engine cold, drain coolant until level
drops below cylinder head. Refer to Group 7, Cooling
System.
(2) Disconnect coolant sensor electrical connector.
(3) Remove coolant sensor.
INSTALLATION
(1) Install coolant sensor. Tighten sensor to 7 N´m
(60 in. lbs.) torque.
(2) Attach electrical connector to sensor.
(3) Fill cooling system. Refer to Group 7, Cooling
System.
CRANKSHAFT POSITION SENSOR
REMOVAL
(1) Raise and support vehicle.
(2) Disconnect crankshaft position sensor electrical
connector from the wiring harness connector (Fig. 4).
(3) Remove crankshaft position sensor retaining
bolt.
(4) Pull crankshaft position sensor straight up out
of the transaxle housing.
INSTALLATION
NOTE: If the removed sensor is to be reinstalled,
clean off the old spacer on the sensor face. A NEW
SPACER must be attached to the sensor face before
installation. If the sensor is being replaced, confirm
that the paper spacer is attached to the face of the
new sensor (Fig. 5).
(1) Install sensor in transaxle and push sensor
down until contact is made with the drive plate.
While holding the sensor in this position, and install
and tighten the retaining bolt to 11.9 N´m (105 in.
lbs.) torque.
(2) Raise and support vehicle.
(3) Connect crankshaft position sensor electrical
connector to the wiring harness connector.
THROTTLE POSITION SENSOR
Refer to Group 14, Fuel Injection Section, for
Removal/Installation.
Fig. 3 Manifold Absolute Pressure Sensor
Fig. 4 Crankshaft Position Sensor Connector
Fig. 5 Crankshaft Position Sensor and Spacer
NSIGNITION SYSTEM 8D - 25
REMOVAL AND INSTALLATION (Continued)

WIPER ARM
CAUTION: The Driver side wiper arm must be parked
above the passenger side. Failure to do so will result
in damage to the arms, blades, or system.
REMOVAL
(1) Disengage the clip holding outside end of the
wiper arm pivot cover to the wiper arm.
(2) Lift the arm cap upward.
(3) Remove the nut holding wiper arm to the wiper
pivot.
(4) Using a suitable two jaw puller, separate the
wiper arm from the wiper pivot (Fig. 11).
INSTALLATION
(1) Verify that the wiper motor and linkage are in
the park position.
(2) Place the wiper arm in position over the wiper
pivot (Fig. 12). Refer to Alignment.
(3) Install the nut to hold the wiper arm to the
wiper pivot. Tighten nut to 35 N´m (26 ft. lbs.).
(4) Push the arm cap cover down.
(5) Engage clip to the hold outside end of wiper
arm pivot cover to the wiper arm.
WIPER UNIT
REMOVAL
(1) Remove the wiper arms.
(2) Remove the cowl cover. Refer to Group 23 Body
for proper procedure.
(3) Release the hood latch and open hood.
(4) Disconnect the positive lock on the wiper unit
wire connector (Fig. 13).
(5) Disconnect the wiper unit wire connector from
the engine compartment wire harness.
(6) Disconnect the windshield washer hose from
coupling inside unit.(7) Disconnect the drain tubes from nipples on bot-
tom of the wiper unit.
(8) Remove nuts holding wiper unit to lower wind-
shield fence.
(9) Remove bolts holding the wiper unit to the
dash panel (Fig. 14).
(10) Lift wiper unit from weld-studs on lower
windshield fence.
CAUTION: Do not allow wiper unit to rest on brake
master cylinder reservoir, damage to brake system
can result.
(11) Remove wiper unit.
INSTALLATION
For installation, reverse the above procedure.
WIPER LINKAGE
REMOVAL
(1) Remove the windshield wiper unit from vehicle.
Fig. 11 Wiper Arm Removal
Fig. 12 Wiper Arm Adjustment
Fig. 13 Wiper Unit Wire Connector
NSWINDSHIELD WIPERS AND WASHERS 8K - 7
REMOVAL AND INSTALLATION (Continued)

need to be reground to prevent seal damage when
the valve is installed.
VALVE INSTALLATION
(1) Coat valve stems with clean engine oil and
insert in cylinder head.
(2) Install new valve stem seals on all valves using
a valve stem seal tool (Fig. 21). The valve stem seals
should be pushed firmly and squarely over valve
guide.CAUTION: When oversize valves are used, the cor-
responding oversize valve seal must also be used.
Excessive guide wear may result if oversize seals
are not used with oversize valves.
(3) Install valve springs and retainers. Compress
valve springs only enough to install locks, taking
care not to misalign the direction of compression.
Nicked valve stems may result from misalignment of
the valve spring compressor.
CAUTION: When depressing the valve spring
retainers with valve spring compressor the locks
can become dislocated. Check to make sure both
locks are in their correct location after removing
tool.
(4) Check the valve spring installed height B after
refacing the valve and seat (Fig. 20). Make sure mea-
surements are taken from top of spring seat to the
bottom surface of spring retainer. If height is greater
than 38.75 mm (1.525 in.), install a .762 mm (0.030
inch.) spacer under the valve spring seat to bring
spring height back within specification.
(5) Install rocker arm shafts as previously
described in this section.
(6) Checking dry lash. Dry lash is the amount of
clearance that exists between the base circle of an
installed cam and the rocker arm roller when the
adjuster is drained of oil and completely collapsed.
Specified dry lash is 1.17 mm (0.046 in.) for intake
and 1.28 mm (0.050 in.) for exhaust. After performing
dry lash check, refill adjuster with oil and allow 10
minutes for adjuster/s to bleed down before rotating
cam.
REMOVAL AND INSTALLATION
ENGINE MOUNTÐFRONT
REMOVAL
(1) Support the engine and transaxle assembly
with a floor jack so it will not rotate.
(2) Remove the front engine mount through bolt
from the insulator and front crossmember mounting
bracket (Fig. 22).
(3) Remove six screws from air dam to allow
access to the front mount screws.
(4) Remove the front engine mount screws and
remove the insulator assembly.
(5) Remove the front mounting bracket, if neces-
sary (Fig. 22).
INSTALLATION
(1) Reverse removal procedure for installation and
tighten fasteners in this order. For engine mount
Fig. 19 Refacing Valve Seats
Fig. 20 Checking Spring Installed Height and Valve
Tip Height Dimensions
Fig. 21 Valve Stem Oil Seal Special Tool C4745
NS2.4L ENGINE 9 - 23
SERVICE PROCEDURES (Continued)

ENGINE ASSEMBLY
REMOVAL
(1) Perform fuel pressure release procedure. Refer
to Group 14, Fuel System for procedure. Remove fuel
line to fuel rail.
(2) Disconnect battery.
(3) Remove Air cleaner and hoses.
(4) Drain cooling system. Refer to Group 7, Cooling
System for procedure.
(5) Remove upper radiator hose and remove radia-
tor fans. Refer to Group 7, Cooling System for proce-
dure.
(6) Remove lower radiator hose.
(7) Disconnect automatic transmission cooler lines
and plug, if equipped.
(8) Disconnect transmission shift linkage.
(9) Disconnect throttle body linkage.
(10) Disconnect engine wiring harness.
(11) Disconnect heater hoses.
(12) Discharge Air Conditioning System. Refer to
Group 24, Air Conditioning for procedure.
(13) Hoist vehicle and remove right inner splash
shield. Remove wheels and tires.
(14) Loosen power steering belt for pump removal.
Refer to Group 7, Cooling System for procedure.
(15) Remove axle shafts. Refer to Group 2, Suspen-
sion and Driveshafts for procedure.
(16) Disconnect exhaust pipe from manifold.
(17) Remove front and rear engine mount brackets
from the body.
(18) Remove bending braces and front engine
mount bracket. Remove transmission inspection
cover.
(19) Mark flexplate to torque converter and
remove torque converter bolts.
(20) Install front engine mount bracket.
(21) Lower vehicle.
(22) Remove power steering pump. Set pump
aside.
(23) Remove A/C lines at compressor and cap.
(24) Remove ground straps to body.
(25) Raise vehicle enough to allow engine dolly
Special Tool 6135, cradle Special Tool 6710 with
Posts Special Tool 6848 and Adaptor Special Tool
8130 to be installed under vehicle (Fig. 27).
(26) Loosen cradle posts to allow movement for
proper positioning. Locate two rear posts (right side
of engine) into the holes on the engine bedplate.
Locate the two front posts (left side of engine) on the
front engine bracket and A/C compressor bracket
(Fig. 27). Lower vehicle and position cradle mounts
until the engine is resting on mounts. Tighten
mounts to cradle frame. This will keep mounts from
moving when removing or installing engine and
transmission.(27) Lower vehicle so the weight ofONLY THE
ENGINE AND TRANSMISSIONare on the cradle.
(28) Remove engine and transmission mount bolts.
(29) Raise vehicle slowly. It may be necessary to
move the engine/transmission assembly on the cradle
to allow for removal around the body.
INSTALLATION
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine and transmission.
(2) Align engine and transmission mounts to
attaching points. Install mounting bolts at the right
engine and left transmission mounts. Refer to proce-
dures outlined in this section.
(3) Slowly raise vehicle enough to remove the
engine dolly and cradle Special Tools 6135 and 6710.
(4) Install axle shafts. Refer to Group 2, Suspen-
sion and Driveshafts for procedure.
(5) Install transmission and engine braces and
splash shields.
(6) Connect exhaust system to manifold. Refer to
Group 11, Exhaust System and Intake Manifold for
procedure and torque specifications.
(7) Install power steering pump. Refer to Cooling
System Group 7, Accessory Drive Section for belt ten-
sion adjustment.
(8) Install A/C compressor hoses. Refer to Group
24, Heater and Air Conditioning for procedure.
(9) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive Section for belt ten-
sion adjustment.
(10) Install front and rear engine mounts. Refer to
this section for procedure.
(11) Install inner splash shield. Install wheels and
tires.
(12) Connect automatic transmission cooler lines,
and shift linkage. Refer to Group 21, Transmission
for procedures.
(13) Connect fuel line and heater hoses.
(14) Install ground straps. Connect engine and
throttle body connections and harnesses. Refer to
Group 8, Electrical for procedure.
(15) Connect throttle body linkage. Refer to Group
14, Fuel System for procedure.
(16) Install radiator fans. Install radiator hoses.
Fill cooling system. Refer to Group 7, Cooling System
for filling procedure.
(17) Connect battery.
(18) Install air cleaner and hoses.
(19) Install oil filter. Fill engine crankcase with
proper oil to correct level.
(20) Start engine and run until operating temper-
ature is reached.
(21) Adjust transmission linkage, if necessary.
9 - 26 2.4L ENGINENS
REMOVAL AND INSTALLATION (Continued)