2.4L Engine replacing on Chrysler And Dodge Van?

The complete step by step detailed procedure for replacing 2.4L engine on Dodge Caravan and Chrysler Town and Country car/ van models.

The procedure  with diagrams is as follows:-----

Removal & Installation

2.4L Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Drain the cooling system.
3. Drain the engine oil.
4. Relieve the fuel system pressure.
5. Recover the A/C refrigerant.
6. Remove or disconnect the following:
   
   NOTE

   When the transaxle lines are removed from the fittings at the transaxle damage to the inner wall of the hose will occur. To prevent leakage, cut the cooler hoses off flush at the transaxle fitting and use a service cooler hose splice kit upon installation.
   
   
   
   
   Negative battery cable

   Air cleaner and hoses

   Fuel line

   Vacuum hoses

   Radiator fans

   Radiator hoses
   
   
   
   
   Transaxle cooler lines, cut the lines flush at the transaxle fittings

   Transaxle shift linkage

   Throttle body linkage

   Engine wiring harness

   Heater hoses

   Front wheels

   Right inner splash shield

   Drive belts

   Axle halfshafts

   Crossmember cradle plate

   Exhaust front pipe

   Front motor mount

   Structural collar

   Rear motor mount

   Power steering pump. Pinch off the supply hose at the pump, disconnect the hose but leave the pressure line attached and then set the pump assembly aside.

   A/C compressor lines

   Body ground straps
7. Raise the vehicle enough to position dolly 6135, cradle tool 6710 with posts 6848 under vehicle.
8. Loosen the cradle posts to allow movement for proper positioning. Position the two rear posts (right side of engine) into the engine bedplate holes. Position the two front posts (left side of engine) on the oil pan rails. Lower the vehicle and position the cradle mounts until the engine is resting on the mounts and then tighten the mounts to the cradle frame to prevent mounts from moving when removing/installing the powertrain assembly.
9. Attach safety straps around the engine-to-cradle assembly. Lower the vehicle so the weight of the powertrain assembly, not the vehicle are on the cradle. 
   
   
   
   Fig. Chrysler powertrain support tools
10. Remove the engine and transmission bolts.
11. Raise the vehicle away from the powertrain.

To install:

1. Lower the vehicle over the powertrain.
2. Align the engine and transmission mounts to their attaching points. Install and tighten the right mount-to-rail and engine and left mount-to-frame brackets as shown in the two accompanying illustrations.
3. Remove the safety straps and the dolly.
4. Install the rear mount bracket and through bolt. 

Fig. Right mount-to-rail and engine installation-2.4L engine

Fig. Left mount-to-frame bracket installation-2.4L engine

1. Install or connect the following:
   
   
   Torque converter

   Axle halfshafts
   
   

   

   

   Fig. Structural collar and bending strut torque sequence-2.4L engine

   
   
   

   

   

   Fig. Exploded view of the right side engine hydro-type mount-2.4L engine

   
   
   

   

   

   Fig. Exploded view of the front mount and bracket assembly-2.4L engine

   
   
   

   

   

   Fig. Exploded view of the left mount and bracket assembly-2.4L engine
2. Install the bending struts and structural collar, as follows:
   1. Step 1: Position the collar between the transaxle and oil pan and install bolts hand tight.
   2. Step 2: Position the collar to oil pan bolts and install bolts hand tight.
   3. Step 3: Tighten collar to transaxle bolts to 75 ft. lbs. (101 Nm).
   4. Step 4: Tighten collar to oil pan bolts to 40 ft. lbs. (54 Nm).
   5. Step 5: Install the engine front mount assembly.
3. Install or connect the following:
   
   
   Exhaust front pipe

   Crossmember cradle plate

   Power steering pump and lines

   A/C compressor lines

   Drive belts

   Right inner splash shield

   Axle halfshafts

   Front wheels

   Transaxle cooler lines using a splice service kit

   Transaxle shift linkage

   Heater hoses

   Body ground straps

   Engine wiring harness

   Vacuum lines

   Throttle body linkage

   Engine cooling fans

   Fuel line

   Radiator hoses

   Air cleaner and hoses

   Negative battery cable
4. Fill the cooling system.
5. Fill the engine with clean oil.
6. Recharge the A/C system.
7. Start the engine and check for leaks.

These details will help.

Thanks.           

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html