Chrysler Stratus Convertible. Manual — part 388
(18) Install battery tray and battery. Set Power-
train Control Module (PCM) into place.
(19) Install air cleaner and hoses.
(20) Evacuate and charge air conditioning system.
Refer to Group 24, Heating and Air Conditioning for
procedures.
(21) Install oil filter. Fill engine crankcase with
proper oil to correct level.
(22) Start engine and run until operating temper-
ature is reached.
(23) Adjust transmission linkage, if necessary.
INTAKE MANIFOLD
FUEL SYSTEM PRESSURE RELEASE PROCEDURE
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING SYSTEM COMPONENTS. SER-
VICE VEHICLES IN WELL VENTILATED AREAS AND
AVOID IGNITION SOURCES. NEVER SMOKE WHILE
SERVICING THE VEHICLE.
To release fuel pressure, refer to Group 14, Fuel
System for procedure.
REMOVAL
(1) Perform fuel system pressure release procedure
before attempting any repairs.
(2) Disconnect
negative
cable
from
auxiliary
jumper terminal (Fig. 32).
(3) Remove air inlet resonator. Refer to Group 14,
Fuel System for procedure.
(4) Perform fuel system pressure relief procedure
and disconnect the fuel supply line quick connect at
the fuel rail assembly. Refer to Group 14, Fuel Sys-
tem for procedure.
WARNING: WRAP SHOP TOWELS AROUND HOSE
TO CATCH ANY GASOLINE SPILLAGE.
(5) Remove fuel rail assembly attaching screws
and remove fuel rail assembly from engine. Cover
injector holes with a suitable covering.
CAUTION: Do not set fuel injectors on their tips,
damage may occur to the injectors
Fig. 31 Positioning Engine Cradle Support Post
Mounts
1 – SAFETY STRAPS
2 – PLACE REAR POSTS INTO LOCATING HOLES
3 – SPECIAL TOOL 6848
4 – SPECIAL TOOL 6710
5 – SPECIAL TOOL 6135
6 – SAFETY STRAPS
7 – PLACE FRONT POST UNDER BLOCK FLANGE
Fig. 32 Auxiliary Jumper Terminal
1 – AUXILIARY JUMPER TERMINAL
2 – LEFT STRUT TOWER
3 – AIR CLEANER HOUSING
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2.0L SOHC ENGINE
9 - 25
REMOVAL AND INSTALLATION (Continued)
(6) Remove accelerator and speed control cables
from throttle lever and bracket. Refer to Group 14,
Fuel System for procedures.
(7) Disconnect idle air control (IAC) motor and
throttle position sensor (TPS) wiring connectors (Fig.
33).
(8) Disconnect intake air temperature electrical
connector (Fig. 34).
(9) Disconnect leak detection pump and PCV
hoses.
(10) Disconnect knock sensor electrical connector
and disconnect wiring harness from tab located on
the intake manifold (Fig. 34).
(11) Remove transaxle to throttle body support
bracket fasteners at the throttle body and loosen the
fastener at the transaxle end.
(12) Remove EGR tube bolts at the valve and at
the intake manifold (Fig. 35). Remove tube from
engine and discard gaskets.
(13) Remove the intake manifold to inlet water
tube support fastener (Fig. 36).
(14) Remove intake manifold fasteners and washer
assemblies. Remove intake manifold.
INSTALLATION
Replace all O-ring seals (Fig. 37). All intake mani-
fold fasteners and washers are to be discarded and
replaced with NEW fasteners and washers.
(1) Install
new
intake
manifold
O-ring
seals.
Tighten fasteners to 12 N·m (105 in. lbs.) in sequence
shown in (Fig. 36).
(2) Remove covering from fuel injector holes and
insure the holes are clean. Install fuel rail assembly
to intake manifold. Tighten screws to 23 N·m (200 in.
lbs.).
(3) Connect PCV and brake booster hoses.
(4) Inspect quick connect fittings for damage,
replace if necessary. Refer to Group 14, Fuel System
for procedure. Lubricate tube with clean engine oil.
Connect fuel supply hose to fuel rail assembly. Check
connection by pulling on connector to insure it locked
into position.
(5) Install throttle body. Tighten fasteners to 22
N·m (200 in. lbs.). Install transaxle to throttle body
support bracket and tighten to 12 N·m (105 in. lbs.)
Fig. 33 Idle Air Control (IAC) Motor, Throttle
Position Sensor (TPS) Wiring Connectors, and
Vacuum Hose Connection.
1 – IDLE AIR CONTROL MOTOR
2 – THROTTLE POSITION SENSOR
Fig. 34 Intake Manifold Electrical Connectors and
Vacuum Hose Connections
1 – MAP SENSOR
2 – INTAKE AIR TEMPERATURE SENSOR
3 – VAPOR HOSE CONNECTION
4 – KNOCK SENSOR
5 – BRAKE BOOSTER HOSE CONNECTION
Fig. 35 Tube Assembly—Typical
1 – EGR TUBE TO INTAKE MANIFOLD FASTENERS
2 – EGR VALVE TO TUBE FASTENERS
9 - 26
2.0L SOHC ENGINE
JX
REMOVAL AND INSTALLATION (Continued)
at the throttle body first. Next tighten the bracket at
the transaxle.
(6) Connect manifold absolute pressure (MAP) and
intake air temperature sensor wiring connectors.
(7) Connect knock sensor electrical and starter
relay connectors. Connect wiring harness to intake
manifold tab.
(8) Connect Idle Air Control (IAC) motor and
Throttle Position Sensor (TPS) wiring connectors.
(9) Connect vacuum hoses to throttle body.
(10) Install accelerator and speed control cables to
their bracket and connect them to the throttle lever.
Refer to Group 14, Fuel System Throttle Body Instal-
lation procedure.
(11) With new EGR gaskets in position, loosely
assemble the EGR tube onto valve and intake mani-
fold finger tight. Tighten tube fasteners at the EGR
valve first to 11 N·m (95 in. lbs.). Then, tighten the
intake manifold side fasteners to 11 N·m (95 in. lbs.).
(12) Connect negative cable to auxiliary jumper
terminal.
(13) With the DRB scan tool use ASD Fuel System
Test to pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is
selected.
EXHAUST MANIFOLD
REMOVAL
(1) Disconnect exhaust pipe from manifold.
(2) Remove the entire exhaust system. Refer to
Group 11, Exhaust System for procedure.
(3) Remove exhaust manifold heat shield (Fig. 38).
(4) Disconnect oxygen sensor electrical connector.
(5) Remove exhaust manifold retaining fasteners
and remove exhaust manifold (Fig. 39).
(6) Remove and discard manifold gasket.
INSTALLATION
(1) Install new manifold gasket. DO NOT APPLY
SEALER.
(2) Position exhaust manifold in place. Tighten fas-
teners, starting at center and progressing outward in
both directions to 23 N·m (200 in. lbs.). Repeat this
procedure until all fasteners are at specified torque.
(3) Connect oxygen sensor electrical connector.
(4) Install exhaust manifold heat shield.
(5) Install exhaust system. Refer to Group 11,
Exhaust System for procedure.
(6) Attach exhaust pipe with gasket to the mani-
fold and tighten fasteners to 28 N·m (250 in. lbs.).
Fig. 36 Intake Manifold Tightening Sequence
1 – INTAKE MANIFOLD TO WATER INLET SUPPORT
Fig. 37 Intake Manifold O-Rings
1 – THROTTLE BODY TO MANIFOLD GASKET
2 – INJECTOR RAIL MOUNTS
3 – CAPTIVE O-RING GASKET
Fig. 38 Exhaust Manifold Heat Shield
1 – HEAT SHIELD ATTACHING SCREWS
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2.0L SOHC ENGINE
9 - 27
REMOVAL AND INSTALLATION (Continued)
CYLINDER HEAD COVER
REMOVAL
(1) Disconnect make-up air (Fig. 40) and PCV (Fig.
41) hoses from cylinder head cover.
(2) Remove ignition coil and spark plug cables
(Fig. 42).
(3) Remove cylinder head cover bolts.
(4) Remove cylinder head cover.
INSTALLATION
(1) Clean gasket surfaces. Inspect gasket and seals
(Fig. 43). Replace as necessary. For replacement of
spark plug tube seals, refer to Spark Plug Tube Seals
in this section for procedure.
CAUTION: Do not attempt to loosen or remove baf-
fle plate attaching screws. The screws are self-tap-
ping, and in the attempt to retighten, thread damage
(stripping) will result.
(2) Install cylinder head cover and gasket. Tighten
bolts to 12 N·m (105 in. lbs.).
(3) Install ignition coil and spark plug cables (Fig.
42). Tighten ignition coil fasteners to 12 N·m (105 in.
lbs.).
(4) Connect make-up air (Fig. 40) and PCV (Fig.
41) hoses.
Fig. 39 Exhaust Manifold
1 – HEATED OXYGEN SENSOR
Fig. 40 Make-Up Air Hose
Fig. 41 PCV Valve Hose
Fig. 42 Ignition Coil and Spark Plug Cables
1 – IGNITION COILS
2 – SPARK PLUG CABLE
3 – SPARK PLUG INSULATOR
9 - 28
2.0L SOHC ENGINE
JX
REMOVAL AND INSTALLATION (Continued)
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