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Home › Jeep › 2021 › Renegade Trailhawk › Repair and Diagnosis › External Pages › Different variant/trim › Section 2 (2.4L Engine (Service Information)) › Engine Block › Rod, Piston And Connecting › Removal And Installation › Installation

Removal And Installation: Installation

WARNING: This page is about a different variant/trim than selected.
  1. If required, select and fit new piston and connecting rod assemblies to the engine block. Refer to ROD, PISTON AND CONNECTING, STANDARD PROCEDURE .
  2. If required, hone the cylinder bores. Refer to CYLINDER BORE DEGLAZING  .
  3. If removed, install the piston rings. Refer to REMOVAL AND INSTALLATION  .
    GC0095425Courtesy of CHRYSLER GROUP, LLC
  4. Position the piston ring end gaps as follows:
    • Oil ring expander gap (5)
    • Oil ring lower side rail end gap (4)
    • Oil ring upper side rail end gap (1)
    • No. 2 (intermediate) ring end gap (5)
    • No. 1 (upper) ring end gap (2)
    GC0152767Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Typical I4 engine configuration shown.

    NOTE:

    Ensure the position of the ring end gaps does not change when installing the ring compressor (2).

  5. Lubricate the piston rings with clean engine oil. Position the (Special Tool No. C-385, Compressor, Piston) (2) over the piston and rings. Tighten the compressor (2).
    NOTE:

    Install the rod bearings in pairs. Do not mix sizes or use a new bearing half with an old bearing half.

  6. Install the bearing shell (7) on the connecting rod with the tang inserted into the machined groove in the rod. Lubricate the bearing surface with clean engine oil.
  7. Install the (Special Tool No. 10281, Pins, Connecting Rod Guide) (6) on the connecting rod.
    CAUTION:

    Care must be taken not to nick crankshaft journals, as engine damage may occur.

    GC0169235Courtesy of CHRYSLER GROUP, LLC
  8. The piston crowns are stamped with an arrow (1). The piston and connecting rod assemblies must be installed so the arrow points toward the front of the engine.
  9. Wipe the cylinder bore clean and lubricate with clean engine oil.
  10. Rotate the crankshaft until the connecting rod journal is on the center of cylinder bore.
    CAUTION:

    Avoid contact with the piston oil cooler jet(s). Positioning of the oil cooler jet(s) is critical for proper engine operation.

  11. Insert the piston and connecting rod into the cylinder bore and carefully position the guide pins over the crankshaft journal.
  12. Tap the piston down in the cylinder bore using a hammer handle while guiding the connecting rod into position over the rod journal.
    GC0152767Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Typical I4 engine configuration shown.

    CAUTION:

    The connecting rod bolts must not be reused. Always replace the connecting rod bolts whenever they are loosened or removed.

  13. Install the bearing shell (5) on the connecting rod cap (3) with the tang inserted into the machined groove in the cap. Lubricate the bearing surface with clean engine oil.
    NOTE:

    Do not lubricate the threads of the connecting rod cap fasteners (4).

  14. Install the connecting rod cap and bearing with the tang on the same side as the rod. Tighten the NEW  connecting rod cap fasteners (4) to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  15. If required, check the connecting rod side clearance. Refer to ROD, PISTON AND CONNECTING, STANDARD PROCEDURE .
  16. Repeat the previous steps for each piston being installed.
    GC0104468Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    The main bearing cap bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced.

  17. Check the main bearing cap fasteners for necking by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) the fastener must be replaced.
    GC0169583Courtesy of CHRYSLER GROUP, LLC
  18. Remove the temporarily installed cap fasteners from main bearing caps 2, 3 and 5. Install the bearing beam (1) with its longer fasteners so that the <FRT indication (2) is pointing to the front of the engine.
    Fig 1: Main Bearing Cap Bolts Tightening Sequence
    GC0162220Courtesy of CHRYSLER GROUP, LLC
  19. Tighten the ten main bearing cap fasteners in the sequence shown, following this 3 step torque plus angle method. Tighten according to the following torque values:
    • Step 1: All to 15 N.m (11 ft. lbs.)
    • Step 2: All to 45 N.m (33 ft. lbs.)
    • Step 3: All an additional 45° Turn Do not use a torque wrench for this step. 
    GC0121276Courtesy of CHRYSLER GROUP, LLC
  20. Clean the ladder frame sealing surfaces with isopropyl alcohol in preparation for sealant application.
    CAUTION:

    Engine assembly requires the use of a unique sealant that is compatible with engine oil. Using a sealant other than Mopar® Engine Sealant RTV Silicone Rubber Adhesive may result in engine fluid leakage.

    CAUTION:

    Following the application of Mopar® Engine Sealant RTV Silicone Rubber Adhesive to the gasket surfaces, the components must be assembled within 10 minutes and the attaching fasteners must be tightened to specification within the next 10 minutes. Prolonged exposure to the air prior to assembly may result in engine fluid leakage.

  21. Apply a 2 mm bead of Mopar® Engine Sealant RTV Silicone Rubber Adhesive as shown in illustration.
    Fig 2: Ladder Frame Bolts Tightening Sequence
    GC0121277Courtesy of CHRYSLER GROUP, LLC
  22. Install the ladder frame and tighten the twelve fasteners in the sequence shown, following this 2 step method. Tighten according to the following torque values:
    • Step 1: All to 10 N.m (89 in. lbs.).
    • Step 2: All to 26 N.m (19 ft. lbs.).
    GC0169512Courtesy of CHRYSLER GROUP, LLC
  23. If removed, install the crankshaft sprocket key (2) in the crankshaft.
  24. Install the crankshaft sprocket (1).
    GC0169024Courtesy of CHRYSLER GROUP, LLC
  25. Align the timing chain onto the crank sprocket mark (2) using the painted link (1) as a guide.
    GC0084105Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    The balance shaft/oil pump assembly bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts must be replaced.

  26. Check the balance shaft/oil pump fasteners for necking by holding a scale or straight edge against the threads. If all the threads do not contact the scale (2) the fastener must be replaced.
    GC0165462Courtesy of CHRYSLER GROUP, LLC
  27. Align the timing chain onto the balance shaft/oil pump sprocket mark using the painted link (1) as a guide.
  28. With the rear of the balance shaft/oil pump assembly on a slight angle, position the gear into the chain links and install the balance shaft/oil pump assembly on the ladder frame. Make sure the paint marks are aligned.
    Fig 3: Balance Shaft And Oil Pump Bolts Tightening Sequence
    GC0082446Courtesy of CHRYSLER GROUP, LLC
  29. Install the four balance shaft/oil pump fasteners finger tight.
  30. Tighten the balance shaft/oil pump bolts in the sequence shown, following the 3 step torque plus an ending torque angle method. Tighten according to the following torque values:
    • Step 1: All to 15 N.m (11 ft. lbs.)
    • Step 2: All to 29 N.m (22 ft. lbs.)
    • Step 3: All an additional 90° Do not use a torque wrench for this step. 
    GC0084902Courtesy of CHRYSLER GROUP, LLC
  31. Reset the balance shaft/oil pump chain tensioner by pushing the plunger inward and installing a pin to hold the plunger in the retracted position.
    GC0169019Courtesy of CHRYSLER GROUP, LLC
  32. Install the fixed chain guide (7) with two fasteners (6) tightened to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  33. Install the tensioner arm (1) with the fastener (2) tightened to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  34. Install the tensioner (4) with the two bolts (5) tightened to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  35. Remove the tensioner pin (3) from the tensioner (4).
    GC0164851Courtesy of CHRYSLER GROUP, LLC
  36. Using the (Special Tool No. C-4171, Driver Handle, Universal), (Special Tool No. 9706, Installer, Crankshaft Rear Oil Seal) and (Special Tool No. 9509, Installer, Oil Seal) (1), install a NEW  rear crankshaft oil seal.
    GC0169431Courtesy of CHRYSLER GROUP, LLC
  37. If equipped, install the intermediate shaft bearing housing (1) with the three fasteners (2) tightened to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0165547Courtesy of CHRYSLER GROUP, LLC
  38. Install the motor oil cooler, engaging the reference centering with the tab (a) shown in the figure and tighten the union.
  39. Install the heat shield and tighten the fasteners.
  40. Lubricate the seal with engine oil and mount the engine oil filter tightening it completely by hand.
  41. Connect the water flow and return pipes to the engine oil cooler and tighten the clamps.
    GC0169127Courtesy of CHRYSLER GROUP, LLC
  42. Install the Variable Valve Actuation Assembly (VVAA) oil supply filter (1) in the engine block.
    GC0164674Courtesy of CHRYSLER GROUP, LLC
  43. Position the cylinder head gasket engaging the centering bushings.
  44. Place sealant on the cylinder head gasket at the points indicated (1) in the figure.
    Fig 4: Cylinder Head Bolts Tightening Sequence
    GC0163176Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    For each tightening sequence, follow the order shown. 

  45. Install the cylinder head and fasteners securing the cylinder head. Torque all bolts to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0163524Courtesy of CHRYSLER GROUP, LLC
  46. Install the hydraulic tappets (1).
    GC0165519Courtesy of CHRYSLER GROUP, LLC
  47. Install the camshaft (1) into the cylinder head.
  48. Install the bearing caps (2), respecting the numbering of the cylinders stamped at the top of each cap, and tighten the camshaft cap to cylinder head fasteners to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    NOTE:

    The arrow on the bearing cap "a" must point to the timing side.

    GC0164745Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    During all the handling operations, the MULTIAIR actuator should not be overturned with hydraulic tappets above.

  49. Install a NEW  metal gasket on the cylinder head top.
  50. Position the MULTIAIR actuator into the vehicle, and tighten the front MULTIAIR actuator to cylinder head fastener to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  51. Remove the 2020000090 (EMEA) or (Special Tool No. 10259B, Compressor, MultiAir® Spring) (NAFTA) tool from the MULTIAIR actuator.
  52. Install and tighten the rear MULTIAIR actuator to cylinder head fastener to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0163135Courtesy of CHRYSLER GROUP, LLC
  53. Clean the gasket mating surfaces.
  54. Install a NEW  thermostat housing gasket (1).
    GC0163402Courtesy of CHRYSLER GROUP, LLC
  55. Install the thermostat housing (1) and tighten the fastener finger tight.
    GC0165896Courtesy of CHRYSLER GROUP, LLC
  56. Install the vacuum pump support bracket (1b) and securely tighten fasteners (1a).
    GC0163577Courtesy of CHRYSLER GROUP, LLC
  57. Tighten the thermostat housing fastener (1) in a criss-cross pattern to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0165638Courtesy of CHRYSLER GROUP, LLC
  58. Install the fastener (1b) securing the coolant tube to the thermostat housing and tighten to the proper then bend lock tab to secure fastener (1a). Refer to TORQUE SPECIFICATIONS  .
    GC0169101Courtesy of CHRYSLER GROUP, LLC
  59. Install the timing chain guide (1) with the fasteners (2) tightened to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  60. Install the tensioner arm (4) with the bushing and fastener (3) tightened to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0163893Courtesy of CHRYSLER GROUP, LLC
  61. Verify that the crankshaft key is in the "9 o'clock" in correspondence with the surfaces of contact between the lower and upper crankcase.
  62. Install the chain, align the drive gear with the painted link. If you mount a new chain, the alignment reference is yellow.
    GC0165239Courtesy of CHRYSLER GROUP, LLC
  63. Check that the alignment mark (1) is in the "12 o'clock" position.
    GC0165600Courtesy of CHRYSLER GROUP, LLC
  64. Fit the chain on the camshaft sprocket by matching the gear notch (1a) with the marked link (1b). If you mount a new chain, the alignment reference is yellow.
  65. Align the pin (2) and install the camshaft sprocket.
    GC0166199Courtesy of CHRYSLER GROUP, LLC
  66. Tighten the camshaft sprocket bolt (1) to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0163736Courtesy of CHRYSLER GROUP, LLC
  67. Disengage the pawl (1a) from the rack, compress the piston (1b) and insert the pin lock (1c).
    GC0165061Courtesy of CHRYSLER GROUP, LLC
  68. Install the tensioner (1) and tighten the fasteners to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  69. Remove the locking plunger pin (2).
    GC0165102Courtesy of CHRYSLER GROUP, LLC
  70. Apply a suitable silicone sealant to the engine timing cover to engine block gasket surface (1) as shown in illustration.
    GC0165810Courtesy of CHRYSLER GROUP, LLC
  71. Apply a bead (2 mm) of a suitable silicone sealant (1a) and (1b) to the surfaces indicated in the figure.
    GC0164656Courtesy of CHRYSLER GROUP, LLC
  72. Install the engine timing cover and tighten the mounting fasteners (1) to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0164304Courtesy of CHRYSLER GROUP, LLC
  73. Apply a 2 mm bead of Mopar® Engine Sealant RTV Silicone Rubber Adhesive around the oil pan as shown in illustration.
    GC0165103Courtesy of CHRYSLER GROUP, LLC
  74. Install the oil pan and tighten the fasteners (1) to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  75. Install the A/C compressor mounting bracket and tighten the fasteners (2) to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0165067Courtesy of CHRYSLER GROUP, LLC
  76. Install the A/C compressor with three fasteners (1) and tighten the bolts to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0163703Courtesy of CHRYSLER GROUP, LLC
  77. Install a new front crankshaft oil seal with the (Special Tool No. 9506, Installer, Oil Seal) (1).
    GC0169358Courtesy of CHRYSLER GROUP, LLC
  78. Install the generator mounting bracket (1) with three fasteners (2) tightened to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0165128Courtesy of CHRYSLER GROUP, LLC
  79. If removed, install the accessory drive belt tensioner (1) and tighten the fasteners to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0166120Courtesy of CHRYSLER GROUP, LLC
  80. Install the accessory drive belt idler pulley (1) and tighten the fastener to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0165695Courtesy of CHRYSLER GROUP, LLC
  81. Install the water pump pulley (1a). Tighten the three fasteners (1b) to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0164247Courtesy of CHRYSLER GROUP, LLC
  82. Install the vibration damper onto the crankshaft (1c).
  83. Using the (Special Tool No. 9707, Holder, Vibration Damper) (1a), Install the vibration damper fastener (1b) and tighten to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0163299Courtesy of CHRYSLER GROUP, LLC
  84. Install the alternator, engaging the centering bushing and tighten the fastener (1) to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
  85. Connect the alternator wiring with the fastener (3) and engage the cap (3).
  86. Connect the wire harness connector (2) to the alternator.
    GC0163563Courtesy of CHRYSLER GROUP, LLC
  87. Install the wiring retaining bracket to the cylinder head with the fastener (1) tighten to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0165917Courtesy of CHRYSLER GROUP, LLC
  88. Rotate the belt tensioner (1b) and install the serpentine belt (1c).
    GC0165710Courtesy of CHRYSLER GROUP, LLC
  89. Install new seals on the valve cover (1).
    GC0163546Courtesy of CHRYSLER GROUP, LLC
  90. Apply sealant in the points shown in illustration (1).
    Fig 5: Valve Cover Screws Tightening Sequence
    GC0163584Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Place the studded fasteners in the positions previously marked for installation.

  91. Put into place the valve cover and tighten the screws in the order shown. Tighten the fasteners to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0165511Courtesy of CHRYSLER GROUP, LLC
  92. Install the ignition coils (1) and tighten the fasteners (1) to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  93. Using NEW  gaskets, install the intake manifold and tighten the fasteners to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  94. Install the intake manifold support bracket fasteners and securely tighten.
  95. Install the intake manifold lower support bracket fastener and securely tighten.
  96. Install the intake manifold silencer cover and securely tighten the four fasteners.
  97. Install the fuel rail with injectors and securely tighten the retaining fasteners.
  98. Install the fuel vapor solenoid.
  99. Connect the fuel vapor delivery pipe to the air box.
  100. Install the sound absorber.
  101. Install a NEW  gasket on the inlet plenum.
  102. Install the throttle body, positioning it correctly on the centering pin.
  103. Install the throttle body fasteners and tighten to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  104. Install the throttle body reinforcement bracket and tighten the fastener to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0165500Courtesy of CHRYSLER GROUP, LLC
  105. Connect the pipe (1) that delivers oil vapor to the air capacity airbox.
    GC0169552Courtesy of CHRYSLER GROUP, LLC
  106. Install NEW  vacuum pump O-ring seals (1, 2).
    GC0169012Courtesy of CHRYSLER GROUP, LLC
  107. Install the vacuum pump into the cylinder head opening with two fasteners (1) tightened to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0169172Courtesy of CHRYSLER GROUP, LLC
  108. Install the oil dipstick tube (1) to the engine with the fastener (2) tightened to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0166163Courtesy of CHRYSLER GROUP, LLC
  109. Install a NEW  exhaust manifold gasket onto the cylinder head, taking care that the arrow (a) shown in illustration is pointing downwards.
    GC0164733Courtesy of CHRYSLER GROUP, LLC
  110. Install the manifold catalyst (1c). Tighten the fastener (1b, 1a) to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0163813Courtesy of CHRYSLER GROUP, LLC
  111. Install the catalytic converter support bracket and tighten the fasteners (1) to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
    GC0164712Courtesy of CHRYSLER GROUP, LLC
  112. Install the ground terminal (1) and tighten the fastener securely.
    GC0163622Courtesy of CHRYSLER GROUP, LLC
  113. Install the heat shield of the ground terminal (1) and tighten the fastener securely.
  114. Position the wire harness on the engine and make the following connections:
    • Install the fastener securing the wiring duct on the intake side.
    • Install the fasteners securing the wiring duct on the exhaust side.
    • Connect the knock sensor wire harness connector
    • Connect the crankshaft position sensor wire harness connector
    • Connect the A/C compressor wire harness connector
    • Connect the manifold pressure and temperature sensor wire harness connector and engage the retaining clips
    • Connect the engine oil pressure sensor wire harness connector
    • Connect the throttle body wire harness connector
    • Connect the coolant temperature sensor wire harness connector
    • Connect the purge solenoid wire harness connector
    • Connect the fuel injector wire harness connectors
    • Connect the engine oil temperature sensor wire harness connector
    • Connect the variable valve actuator wire harness connectors
    • Connect the ignition coil wire harness connectors
    • Connect the ground terminal wire harness connector
  115. Install the lower heat shield onto the exhaust manifold and securely tighten the fasteners.
  116. Install the upper heat shield and securely tighten the fasteners.
  117. Install the upstream oxygen sensor support bracket and securely tighten the fasteners then engage the wire harness retainer.
  118. Connect the upstream oxygen sensor wire harness connector.
  119. Connect the downstream oxygen sensor wire harness connector.
  120. Install a NEW  oil drain plug and tighten to the proper torque specification. Refer to TORQUE SPECIFICATIONS  .
  121. Service the engine with the proper quality and quantity of engine oil. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
  122. Install the flexplate and transmission to the engine and install the engine in the vehicle. Refer to REMOVAL AND INSTALLATION  .
  123. Fill the transmission. Refer to FLUID AND FILTER, STANDARD PROCEDURE .
  124. Fill the cooling system. Refer to DRAINING AND FILLING THE COOLING SYSTEM - 2.4L .
  125. Connect the negative battery cable terminal with the IBS to the negative post of the battery and securely tighten the fastener.
  126. Evacuate and charge the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE .
  127. Start engine and check for leaks.
  128. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level. Refer to DRAINING AND FILLING THE COOLING SYSTEM - 2.4L .
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