PT Cruiser 2009 2.2L

2009 Chrysler PT Cruiser
2009 ENGINE 2.2L Diesel - Service Information - PT Cruiser
2009 ENGINE
2.2L Diesel - Service Information - PT Cruiser
DESCRIPTION
DESCRIPTION
Fig. 1: 2.2L Diesel Engine

Courtesy of CHRYSLER LLC
This 2.2 Liter four-cylinder Common Rail Diesel Injection (CDI) engine is an in-line overhead valve diesel
engine . See Fig. 1. This engine utilizes a cast iron cylinder block and an aluminum cylinder head. The engine is
turbocharged and intercooled. This engine also has four valve per cylinder and dual overhead camshafts.
DESCRIPTION SPECIFICATION
Engine 2.2L CDI
Engine Description 4 Cylinder In-Line Engine With 4-Valve
Technology
Fuel Injection System Common Rail Diesel Injection (CDI)
Fuel Diesel
Rated Output 85/4200 kW at RPM
Torque 250/1400-2600 Nm at RPM
Maximum Speed 4600 RPM
Compression Ratio 18:0
Bore/Stroke 88.0/88.3 mm
miércoles, 10 de marzo de 2021 09:01:49

09:01:40 p. m. Page 1 © 2011 Mitchell Repair Information Company, LLC.
Eff. Displacement 2148 cm3
STANDARD PROCEDURE
ENGINE GASKET SURFACE PREPARATION
Fig. 2: PROPER TOOL USAGE FOR SURFACE PREPARATION

To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of
aluminum engine components and multi-layer steel cylinder head gaskets.
Never use the following to clean gasket surfaces:
l Metal scraper (1).

l Abrasive pad or paper to clean cylinder block and head.
l High speed power tool with an abrasive pad or a wire brush (2,3).
miércoles, 10 de marzo de 2021 09:01:40 p. m. Page 2 © 2011 Mitchell Repair Information Company, LLC.
Fig. 3: PROPER TOOL USAGE FOR SURFACE PREPARATION

NOTE: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.
Only use the following for cleaning gasket surfaces:
l Solvent or a commercially available gasket remover

l Plastic or wood scraper (4).
Sealing surfaces must be free of grease or oil residue. Clean surfaces with Mopar® brake parts cleaner (or
equivalent).
COMPRESSION TESTING ENGINE
Fig. 4: #9543 ADAPTER

1. Warm up engine to operating temperature (approximately 80°C, 176°F).
2. Shut off engine.

3. Remove engine cover. See Engine - Removal.
4. Remove injectors. Refer to Fuel System/Fuel Injection/INJECTOR(S), Fuel - Removal .
5. Crank engine several times with the starter to eliminate combustion residues in the cylinders.
6. Insert Adapter 9543 into injector hole of cylinder to be tested. Install injector retainer.
7. Test compression pressure by cranking engine with starter for at least 8 revolutions.
8. Carry out test procedure at the remaining cylinders in the same way.
9. Compare pressure readings obtained with the specified pressures. If the pressure reading is below the
minimum compression pressure or if the permissible difference between the individual cylinders is
exceeded, refer to Engine - Standard Procedure.
2.2L COMPRESSION SPECIFICATION

COMPRESSION SPECIFICATION
Minimum Allowable 18 bar (261 psi.)
Maximum Allowable 3 bar (44 psi.)
Difference Between Cylinders
Average Compression Ratio 24 - 30 bar (348 - 435 psi)
10. Remove Adapter 9543 from cylinder head.

11. Install injectors. Refer to Fuel System/Fuel Injection/INJECTOR(S), Fuel - Installation .
12. Install engine cover. See Engine - Installation.
CYLINDER LEAK DOWN TEST
1. Warm engine to operating temperature.
WARNING: Do not open cooling system unless coolant temperature is below 90°
c (194°f). Risk of injury to skin and eyes as a result of scalding with
hot coolant which splashes out. Risk of poisoning from swallowing
coolant. Open cap slowly and release pressure. Store coolant in
proper containers only. Wear protective gloves, clothing and eye
protection.
NOTE: Turn cap carefully as far as first detent, release pressure, then unscrew
cap.
2. Open cooling system cap at coolant recover pressure container.

4. Unscrew oil filler cap.
5. Remove glow plugs. Refer to Electrical/Ignition Control/PLUG, Glow - Removal .
NOTE: Crank engine at crankshaft in direction of rotation of the engine
(clockwise).
6. Position cylinder to be tested to ignition Top Dead Center (DTC).
NOTE: Calibrate cylinder leak down tester and remove check valve in screw-in
fitting.
7. Connect cylinder leak down tester and follow INSPECTING Instruction.
INSPECTING
NOTE: If crankshaft rotates, install retaining lock for crankshaft/ring gear.
1. Pressurize cylinder with compressed air and read off pressure loss at cylinder leak tester. If excessive
pressure loss exists, determine cause by viewing the paragraph below.
NOTE: If the retaining lock is installed, remove it, rotate engine and install lock
once again.
2. Carry out test of other cylinders in the firing order of engine.
DETERMINING PRESSURE LOSS
If a great pressure loss was detected, listen using a stethoscope around suspected areas, such as the cylinder
head gasket through the air suction area, the exhaust system, the oil filler neck, the pre-chamber, the bore
wholes of the cylinder effected or neighboring cylinders. Observe the coolant in the expansion tank, looking for
traces of bubbles.
The possible causes of pressure loss are:
l If air leak is detected through the prechamber, cylinder bore hole, from a neighboring cylinder or air
bubbles in the coolant expansion tank, pressure loss may be caused by the cylinder head gasket.
l If the air leak occurs in the air suction area, the pressure loss may be caused by the intake valve(s).
l Air leak through the exhaust system, may be caused by the exhaust valve(s).
l Air leak through the oil filler neck, may be caused by piston, ring, or cylinder sleeve.
If none of the above evidence supports a failure, the engine may be assembled and run until operating
temperature is reached. Reconnect engine leak down tester on a warm engine with a few drops of clean engine
oil in the cylinder being tested. Engine oil seals the clearance between the piston and cylinder for a short length
of time. If under this condition a smaller pressure loss occurs for a shorter length of time, it is possible that the
cause is piston, ring or cylinder sleeve related.
CHECKING OIL PRESSURE
2. Remove oil galley plug together with seal at timing case cover.
3. Screw oil pressure gauge adaptor fitting together with seal onto timing case cover.
4. Connect oil pressure gauge to adaptor fitting.
5. Check oil level, adjust with correct engine oil if necessary.
6. Insert temperature of remote thermometer into oil level indicator tube.
WARNING: Use extreme caution when engine is operating. Do not stand in a

direct line with fan. Do not put your hands near pulleys, belts or fan.
Do not wear loose clothes.
CAUTION: Ensure that fan and accessory drive belt DO NOT damage oil
pressure gauge hose.
7. Start engine and bring to operating temperature 90°C (194°F).

8. Record engine oil pressure at idle.
9. Raise engine speed to 3000 RPM and record oil pressure.
10. At normal operating temperature the oil pressure must not drop below 3 bar (44 psi). When engine speed
is raised, oil pressure must rise with out delay and be no less than 3 bar (44 psi) at 3000 RPM.
11. If oil pressure is out of range, determine cause.
REMOVAL
ENGINE COVER
Fig. 5: Engine Cover Mounts

1. Remove engine cover retaining nuts (1). See Fig. 5 .

2. Unclip engine cover (2) from engine cover mounts (3) and remove engine cover from engine.
ENGINE
CAUTION: When removing ancillary components, plug all inlet/outlet and fluid lines
to prevent residual leakage and contamination.
Fig. 6: Battery Location

1 - BATTERY
2 - PASSENGER SEAT
1. Disconnect negative battery (1) cable located under the front passenger seat.
2. Discharge air conditioning (refer to REFRIGERANT SYSTEM EVACUATE ).
3. Drain cooling system (refer to SYSTEM DRAINING ).

1 - ENGINE COVER RETAINING NUTS

2 - ENGINE COVER
3 - ENGINE COVER MOUNTS
4 - ENGINE COVER MOUNTING STUDS
4. Remove engine cover (1). See Engine - Removal.

5. Remove front grille assembly. Refer to Body/Exterior/GRILLE - Removal .
6. Remove upper radiator closure panel. Refer to Body/Exterior/CROSSMEMBER, Radiator -
Removal .
Fig. 8: Air Cleaner Housing Assembly

1 - TURBOCHARGER INLET HOSE

2 - MAF SENSOR RETAINING BOLT
3 - MAF SENSOR
4 - O-RING
5 - MAF SENSOR ELECTRICAL CONNECTOR
6 - AIR CLEANER ASSEMBLY
7 - INLET DUCT
8 - AIR CLEANER HOUSING ASSEMBLY BRACKET
7. Remove air cleaner housing (6) and air inlet hose (7) assembly. See Engine/Air Intake System/BODY,
Air Cleaner - Removal.
8. Remove radiator and A/C condenser. Refer to Cooling/Engine/RADIATOR, Engine Cooling -
Removal .
9. Remove engine compartment lower silencer and accessory drive belt splash shield.
Fig. 9: TIPM Bracket Attaching Bolts - Typical

1 - Totally Integrated Power Module (TIPM)

2 - TIPM BRACKET BOLTS
3 - BATTERY TRAY BOLT
10. Remove power distribution center bracket.

11. Disconnect shift cables at transaxle.
Fig. 10: Disconnecting Clutch Hydraulic Line

1 - QUICK CONNECT FITTING

2 - DISCONNECT TOOL 6638 A
12. Disconnect clutch hydraulic line at transaxle.

13. Disconnect reverse light switch harness connector at transaxle.
14. Disconnect speed sensor harness connector at transaxle.
15. Disconnect wiring at starter and alternator, position wiring harness aside.
16. Disconnect three wiring harness connectors and two ECM harness connectors, position wiring harnesses
aside.
17. Disconnect engine coolant heater harness connector.
Fig. 11: FUEL FILTER

1 - FUEL INLET
2 - FUEL FILTER DRAIN
3 - FUEL FILTER OUTLET
4 - FUEL FILTER DRAIN NIPPLE
5 - FUEL HEATER CONNECTOR
18. Disconnect harness connector (5) at fuel filter/fuel heater.

19. Disconnect fuel lines (1,3) at fuel filter/water separator.
20. Disconnect heater hoses at heater core.
21. Disconnect power brake booster vacuum hose at engine.
22. Disconnect coolant recovery hose at engine.
23. Disconnect coolant recovery hose at coolant pressure recovery container.
24. Disconnect supply hose at power steering fluid reservoir and set aside.
25. Disconnect vacuum hose at turbocharger.
26. Disconnect suction line at A/C compressor and position aside.
27. Remove fastener retaining ground strap to engine.
Fig. 12: Engine Mounting - Right Side

1 - BOLT
2 - RIGHT FENDER
3 - UPPER TORQUE STRUT BRACKET
4 - NUTS
5 - BOLT
6 - UPPER TORQUE STRUT
7 - BOLT
8 - LOWER TORQUE STRUT
9 - BOLT
10 - RIGHT ENGINE MOUNT
28. Remove two fasteners from upper torque strut (6).

29. Disconnect swirl valve actuator hose at actuator.
30. Raise support vehicle.
31. Remove front wheels.
32. Remove two fasteners retaining left strut to steering knuckle.
33. Separate front strut from steering knuckle.
34. Disengage left half shaft tripod joint from output shaft.
NOTE: When removing tripod joint, DO NOT let spline or snap ring drag across
transaxle oil seal lip.
35. Remove left half shaft tripod joint from transaxle while pulling outward on top of the steering knuckle.
36. Support half shaft to prevent damage to seal boot and clamp.
37. Perform steps 34 through 38 to remove right side tripod.
Fig. 13: Splash Shield

1 - RIGHT MOUNT BOLT ACCESS PLUG

2 - FASCIA
3 - SPLASH SHIELD
4 - CRANKSHAFT BOLT ACCESS PLUG
38. Remove inner splash shield (3).

39. Disconnect engine oil pressure sensor harness connector and remove sensor from engine.
40. Disconnect power steering pressure hose at steering gear, position aside.
41. Remove exhaust manifold.
Fig. 14: Pencil Strut

1 - NUT
2 - PENCIL STRUT
3 - NUT
4 - FLAT WASHER
42. Remove pencil strut (2) and lower torque strut (5).
43. Remove inner cooler tube.
Fig. 15: Positioning Engine Cradle Support Post

1 - POST LOCATING HOLES IN BLOCK

2 - POST POSITIONED UNDER BRACKET
3 - POST LOCATING HOLE IN STRUT

4 - SAFETY STRAPS
5 - FLOOR JACK
6 - POST KIT ENGINE CRADLE 6848
7 - DOLLY 6135
8 - CRADLE 6710
44. Position the engine dolly 6135 (7) with the cradle 6710A (8) and Post Kit Engine Cradle 6848 (6)
underneath the engine.
45. Carefully lower the vehicle enough to position the engine above the support posts.
46. Align three support posts with three engine mounting sockets.
47. Position the fourth support post and adaptor underneath engine oil cooler flange.
48. Adjust the height of each support post as necessary and tighten the support posts and cradle fasteners.
49. Carefully lower vehicle enough to seat engine onto support posts.
WARNING: Safety straps must be use to secure engine to the dolly fixture.
50. Install, tighten and lock safety straps (4) around engine and attach them to the cradle.
51. Raise vehicle enough to verify safety straps (4) retain dolly fixture to engine.
52. Lower vehicle so that only the weight of the engine and transmission assembly is on dolly fixture.

1 - BOLT
2 - RIGHT FENDER
4 - NUTS
5 - BOLT
7 - BOLT
9 - BOLT
53. Remove right mount (10) through bolt.
Fig. 17: LEFT MOUNT - TYPICAL

1 - BOLT (2)
2 - MOUNT
3 - BRACKET
54. Remove two left mount through bolts (1).
CAUTION: It may be necessary to adjust the engine and transmission assembly,

with the dolly fixture attached, to successfully clear the engine
compartment.
55. While watching for obstructions, slowly raise the vehicle until the engine and transmission assembly clear
the engine compartment.
INSTALLATION
ENGINE COVER

1. Align engine cover (2) with mounting studs. See Fig. 18 .

2. Firmly press cover onto mounting studs (4).
3. Install retaining nuts (1) at rear of engine cover.
ENGINE

WARNING: Safety straps (4) must be used to secure engine to the dolly fixture.
1. Seat engine onto Post Kit Engine Cradle 6848 then install, tighten and lock safety straps (4) around
engine, securing it to the cradle 6710A.
2. Position the engine and transmission assemblies below vehicle engine compartment.
CAUTION: It may be necessary to adjust the engine and transmission assembly,

with the dolly fixture attached, to successfully clear the engine
compartment.
3. While watching for obstructions, slowly lower the vehicle until the engine and transmission assembly
clearly fit the engine compartment.

4. Install two left mount through bolts (1). See Engine/Engine Mounting/INSULATOR, Engine Mount -
Installation.
Fig. 21: Right Mount Through Bolt

5. Install right mount through bolt (1). See Engine/Engine Mounting/INSULATOR, Engine Mount -
Installation.

6. Remove safety straps (4).

7. Carefully raise the vehicle enough to clear the Cradle 6710A (1) and Post Kit Engine Cradle 6848 (6).
8. Install charge air cooler pipe.

9. Install pencil strut (2) and lower torque strut (5). See Engine/Engine Mounting/STRUT, Torque -
Installation.
10. Install exhaust manifold down pipe.
11. Connect power steering pressure hose at steering gear.
12. Connect oil pressure switch electrical connector.
NOTE: When installing tripod joint, DO NOT let spline or snap ring drag across
transaxle oil seal lip.
13. Pull outward on the right steering knuckle and position the right half shaft tripod joint to the transaxle.
14. Engage right half shaft tripod joint to output shaft.
15. Connect steering knuckle to strut.
16. Install two fasteners retaining strut to knuckle.
17. Perform steps 13 through 16 to install left side tripod joint.

18. Install splash shield (3).

19. Install front wheels.
20. Remove cradle assembly from beneath vehicle and lower vehicle.
21. Connect swirl actuator line at engine.

22. Install two fasteners for the upper torque strut (6).
23. Install ground strap.
24. Connect suction line to A/C compressor.
25. Connect vacuum hose at turbocharger.
26. Connect power steering fluid reservoir supply hose.
27. Connect coolant recovery hose to recovery container.
28. Connect coolant recovery hose to engine.
29. Connect power brake booster vacuum hose to engine.
30. Connect heater hoses to heater core.
Fig. 26: FUEL FILTER

31. Connect fuel lines (1,3) to fuel filter/water separator.

32. Connect harness connector to fuel filter/fuel heater.
33. Connect engine coolant heater harness connector.
34. Connect three wiring harness connectors and two Engine Control Module harness connectors.
35. Connect wiring at starter and alternator.
Fig. 27: Disconnecting Clutch Hydraulic Line

36. Connect speed sensor harness connector to transaxle.

37. Connect reverse light switch harness connector to transaxle.
38. Connect clutch hydraulic line at transaxle.
Fig. 28: PDC Bracket Attaching Bolts - Typical

39. Install power distribution center bracket (2).

40. Install lower engine compartment silencer.
41. Install coolant module assembly and connect radiator fan electrical connector.
42. Install air cleaner inlet housing and air inlet hose.
43. Install upper radiator closure pane. Refer to Body/Exterior/CROSSMEMBER, Radiator -
Installation .
Fig. 29: GRILL REMOVAL

44. Install front grille assembly (2). Refer to Body/Exterior/GRILLE - Installation .

45. Refill cooling system with the appropriate coolant mixture to the proper level (refer to SYSTEM
FILLING - DIESEL ENGINE ).
46. Be sure all oil and fluid levels are adjust to specification.
47. Connect negative battery cable.
48. Start engine and inspect for leaks
49. Check all fluid levels in accordance with owners guide and adjust levels as necessary.
50. Recharge air conditioning (refer to REFRIGERANT SYSTEM CHARGE ).

51. Install engine cover (2). See Engine - Installation.
SPECIFICATIONS
SPECIFICATIONS
SPECIFICATIONS
DESCRIPTION N.m Ft. Lbs. In. Lbs.
Crankcase Ventilation
Screw-Air Charge 11 - 97
Distribution Pipe to Air
Charge Distribution Panel
Cylinder Head
8m-Bolt- Cylinder Head 20 15 -
to Timing Case Cover
Bolt-Front Cover to 14 - 124
Cylinder Head
12m-Bolt-Cylinder Head 60, 90°, 90° 44, 90°, 90° -
to Crankcase (3 stages,
torque, torque angle,
torque angle)
Crankcase, Timing Case Cover, End Cover
Bolt-Crankshaft Bearing
Cap to Crankcase (2
stages, torque, torque 55, 90° 40, 90° -
angle)
Bolt-End Cover to 9 - 80
Crankcase
Bolt-Timing Case Cover 20 15 -
to Crankcase
Plug-Coolant Drain to 30 22 -
Crankcase
Oil Pan
6m-Bolt-Oil Pan to 9 - 80
Crankcase
8m-Bolt-Oil Pan to 20 15 -
Crankcase
Bolt-Oil Pan to End 9 - 80
Cover
Bolt-Oil Pan to Timing 9 - 80
Case Cover
Bolt-Oil Pan to 40 30 -
Transmission Bell
Housing
Plug-Oil Pan to Oil Drain 47 35 -
Connecting Rod
Bolt-Connecting Rod Cap 5,25,90° - 44,221, 90°
to Connecting Rod (3
stage, 1 AND 2 torque, 3
torque angle)
Crankshaft
Bolt-Crankshaft Bearing 55,90° 40.5, 90° -
Cap (2 stage, 1 torque, 2
torque angle
Flywheel, Driven Plate, Vibration Damper, Starter Ring Gear
8.8m-Bolt-Central Bolt of 200,90° 147.5, 90° -
Vibration Damper (2
stage, 1 torque, 2 torque
angle)
10.9m-Bolt-Central Bolt 325,90° 240, 90° -
of Vibration Damper (2
stage, 1 torque, 2 torque
angle)
Bolt-Stretch Shank for 45,90° 33, 90° -
Flywheel or 2 Mass
Flywheel to Crankshaft
(2 stage, 1 torque, 2
torque angle)
Turbo Charger
Bolt-Oil Feed Line to 9/22 - 80-194
Cylinder Head
Bolt-Oil Feed Line to 30 22 -
Turbo Charger
Bolt-Turbo Charger 30 22 -
Support
Bolt-Turbo Charger 20 - 177
Support to Crankcase
Bolt-Oil Outlet Line to 9 - 80
Turbo Charger
Connection-Flange of 30 22 -
Exhaust Manifold to
Turbo Charger
Connection-Turbo 30 22 -
Charger to Front
Catalytic Converter
Charge Air Pipe/Charge Air Cooling
Bolt-Charge Air 16 - 141
Distribution Pipe
Bolt-Inlet Port Shut Off 9 - 80
Positioning Motor to Air
Charge Distribution Pipe
Bolt-Support to Charge 20 - 177
Air Distribution Pipe
Bolt-Support to Engine 40 30 -
Bracket
Clamp-Charge Air 3 - 27
Pipes/Hoses
Belt Tensioning Device
Bolt-Guide Pulley to
35 26 -
Coolant Pump
Bolt-Guide Pulley to
35 26 -
Timing Case Cover
Bolt-V-Belt Tensioning
Device to Tensioning 36 26.5 -
Pulley
Bolt-V-Belt Tensioning
Device to Timing Case 30 22 -
Cover
Exhaust Manifold
Nut-Exhaust Manifold at
30 22 -
Cylinder Head
Position Sensor
Nut/Bolt-Camshaft
Position Sensor to 11 - 97
Cylinder Head Cover
Nut/Bolt-Crankshaft
Position Sensor to Engine 8 - 70
Block
Pre-Glow System
Cylinder Head to Glow
12 - 106
Plug
Starter
Bolt-Starter to Crankcase 42 31 -
Nut-Connection of
14 - 124
Circuit 30
Nut-Connection of
6 - 53
Circuit 50
Alternator
Bolt-Generator to Timing
20 15 -
Case Cover
Bolt-Generator to Cooler
6 - 53
Housing
Bolt-Cooler Housing of
20 - 177
Generator to Crankcase
Nut-B+ Circuit to
13-18 - 115-159
Generator
Nut-D+ Circuit to
5 - 44
Generator
Nut-Collar to V-Belt
80 59 -
Pulley
Oil Pump
Bolt-Oil Pump to
18 - 133
Crankcase
Bolt-Oil Pipe to
8 - 70
Crankshaft Bearing Cap
Oil Filter
Screw Cap to Oil Filter 25 18.5 -
Oil Cooling System
Bolt-Oil-Water Heat
Exchanger to Timing 15 - 133
Cover Case
Oil Level Pressure
Bolt-Dip Stick Guide
14 - 123
Tube to Cylinder Head
Bolt-Oil Level Sensor to
14 - 123
Oil Pan
Coolant Pre- Heater

Coolant Pre-Heater in
35 26 -
Engine Block
Engine Cooling General
Bolt-Belt Pulley to
8-35 6-26 -
Coolant Pump
Bolt-Coolant Pump to
Timing Case Cover 14/20 10-15 -
6m/8m
Bolt-Thermostat Housing
9 - 80
to Cylinder Head
Coolant Drain Plug to
30 22 -
Crankcase
Engine Suspension, Engine Mount, Engine Bracket
Bolt-Engine Bracket to
Crankcase (2 stage, 20, 90° 15, 90° -
torque, torque angle)
Bolt-Engine Mount to
55 40.5 -
Engine Bracket
Bolt-Front Engine Mount
35 26 -
to Front Axle Carrier
Bolt-Rear Engine Cross
40 30 -
Member to Body
Bolt-Rear Engine Mount
to Rear Engine Cross 35 26 -
Member
Bolt/Nut- Rear Engine
40 26 -
Mount to Transmission
Bolt-Shroud to Engine
10 - 88.5
Bracket
Nut-Front Engine Mount
65 48 -
to Engine Bracket
Nut-Engine Mount to
35 26 -
Vehicle Frame
Fuel Filter
Bolt-Clip to Fuel Filter 8 - 70
Bolt- Fuel Filter to
Charge Air Distribution 14 - 124
Pipe
Exhaust System
Bolt- Catalytic Converter
20 - 177
Bracket to Crankcase
Clamp-Connection
Between Front Exhaust 55 41 -
Pipe and Rear Exhaust

System
Clip-Front Catalytic
Converter to Engine 20 - 177
Mount
Nut-Bracket to Tail Pipe 55 40.5 -
Nut-Exhaust Bracket to
Threaded Plate of Center 20 - 177
Exhaust Pipe
Support-Exhaust Bracket
20 - 177
on Transmission
Refrigerant Compressor
Bolt-Refrigerant
Compressor to Timing 20 - 177
Case Cover
Bolt-Refrigerant
20 - 177
Compressor to Bracket
Bolt-Refrigerant Lines to
20 - 177
Refrigerant Compressor
Timing Chain, Chain Tensioner
Bolt-Camshaft Sprocket
18 - 159
to Exhaust Camshaft
Bolt-Intermediate Gear of
High Pressure Pump to 40 29.5 -
Cylinder Head
Timing Chain Tensioner
80 59 -
to Timing Case Cover
Camshaft
Bolt-Camshaft Bearing
9 - 80
Cap to Cylinder Head
Bolt-Driver to Inlet
50 37 -
Camshaft
Common Rail Diesel Injection
Bolt-Banjo Bolt of Leak
20 - 177
Oil Line to Rail
Bolt-Bracket to High
9 - 80
Pressure Pump
Bolt-High Pressure Pump
14 - 124
to Cylinder Head
Bolt-Pre-delivery Pump
to Top Cover of Cylinder 9 - 80
Head
Bolt-Pressure Control
Valve to Rail (2 stage, 3, 5 - 26, 44
torque)
Bolt-Rail to Cylinder
14 - 124
Head
Bolt-Shutoff Valve to
8 - 70
Cylinder Head
Nut-Pressure Line to
Rail/Injector (New, 22/25 16/18.5 -
Reused)
Nut-Pressure Line to
22 16 -
High Pressure Pump/Rail
Screw-Tensioning Claw
to Injector (2 stage, 1 7, 90° - 62, 90°
torque, 2 torque angle)
Rail- Pressure Sensor to
22 16 -
Rail
Pressure Pipe Connection
42 31 -
to Injector
Threaded Rail to Rail 22 16 -
Fuel Cooling System
Bolt-Fuel Cooler to
Charge Air Distribution 14 - 124
Pipe
Heater Booster, Heater Unit
Bolt- Temperature
Controlled Cut Out to
12 - 106
Heater Booster control
Module
Nut-Threaded Stud to
18 - 159
Electronic Heater Booster
SPECIAL TOOLS
SPECIAL TOOLS
Fig. 31: LOCKING PINS - 8929

Fig. 32: #8933 CRANKSHAFT LOCK

Fig. 33: INSTALLER, SEAL - 8936A

Fig. 34: #8937 SLIDE HAMMER

Fig. 35: EXTRACTION CLAW - 8938A

Fig. 36: REMOVER, CRANKSHAFT DAMPER - 9544

Fig. 37: REMOVER/INSTALLER, OIL JET - 8942

Fig. 38: ASSEMBLY SLEEVE - 8944

Fig. 39: #9307 VALVE SERVICE TOOLS

Fig. 40: ASSEMBLY LINKS - 8951

Fig. 41: #8952 ASSEMBLY INSERTS

Fig. 42: REMOVER/INSTALLER, CHAIN LINK - 9312A

Fig. 43: ADAPTER, COMPRESSION TEST - 9543

AIR INTAKE SYSTEM

AIR CLEANER
Removal
REMOVAL
Fig. 44: Air Cleaner Cover - Typical

1. Unfasten clasps on sides of air cleaner housing cover. Lift cover off air cleaner housing. See Fig. 44 .
2. Remove filter element.
3. If necessary, clean the inside of the air cleaner housing.
Installation
INSTALLATION
Fig. 45: Air Cleaner Cover - Typical

1. Install new filter element.

2. Place cover over air cleaner housing. Snap clasps in place.
BODY, AIR CLEANER
Description
DESCRIPTION
The air cleaner housing attaches to the inner fender in front of the left side strut tower. An ambient air duct
supplies underhood air for the engine. It attaches to the lower air cleaner box.
Removal
AIR CLEANER HOUSING


3 - MAF SENSOR
4 - O-RING
7 - INLET DUCT
1. Disconnect turbocharger inlet hose (1) at air cleaner (6). See Fig. 46. .
2. Pull air cleaner housing (6) straight up to remove.
3. Remove the inlet duct (7) from the air cleaner housing (6).
AIR CLEANER BODY


3 - MAF SENSOR
4 - O-RING
7 - INLET DUCT

2. Disconnect turbocharger inlet hose (1) at MAF sensor (3). See Fig. 48 .
Fig. 48: Turbocharger Inlet Hose

3. Disconnect turbocharger inlet hose (1) at turbocharger (2) and remove inlet tube.
Installation
AIR CLEANER HOUSING


3 - MAF SENSOR
4 - O-RING
7 - INLET DUCT
Make sure that the rubber grommets, for the lower pins, are in place when reinstalling the air cleaner housing
(6). The rubber grommet for the Totally Integrated Power Module (TIPM) bracket must be installed also.
1. Install air inlet duct (7) into air cleaner housing (6).
2. Lower air cleaner housing assembly (6) into engine compartment and align studs at bottom of housing
with bracket. Push housing assembly down until fully seated in bracket.
3. Connect turbocharger inlet hose (1) to air cleaner assembly (6).
AIR CLEANER BODY


2 - TURBOCHARGER
1. Connect turbocharger inlet hose (1) at turbocharger (2).


3 - MAF SENSOR
4 - O-RING
7 - INLET DUCT
2. Connect turbocharger inlet hose (1) at MAF sensor (3).

CYLINDER HEAD
STANDARD PROCEDURE
CYLINDER HEAD BOLT INSPECTION
Fig. 52: Measuring Cylinder Head Bolts

1. Measure cylinder head bolts between points as shown. See Fig. 52.
Cylinder Head Bolts Thread Diameter 12 M

- Length When New 102 mm
Maximum Length 104 mm
2. If the cylinder head bolt length is greater than the maximum allowable measurement, replace the cylinder
head bolts.
MEASURE CYLINDER HEAD SURFACE
Fig. 53: Cylinder Head Measurements

1 - CYLINDER HEAD HEIGHT

2 - VALVE SETBACK
NOTE: Only resurface cylinder head contact surface if porous or damaged. IT IS NOT
necessary to rework minor variations in flatness in the longitudinal direction.
1. Disconnect negative battery cable.

2. Remove cylinder head. See Engine/Cylinder Head - Removal.
3. Remove valves.
4. Inspect cylinder head contact surface for flatness, porous and damage.
5. Using a straight edge, measure cylinder head and cylinder block flatness.
6. Measure cylinder head height at point (1) indicated and retain reading. See Fig. 53 .
NOTE: The camshaft housing Must Not be machined. Basic bore of the camshaft
bearings will be altered.
7. Machine cylinder head contact surface, if necessary.

8. Measure cylinder head height (1) at point indicated, record stock removal. See Fig. 53 .
9. Measure valve setback at points (2) indicated. See Fig. 53 .
NOTE: If measurement is less than dimension "2" no further correct valve

clearance compensation is possible; replace valve seat ring or cylinder
head if measurement is greater than specification.
CYLINDER HEAD SPECIFICATIONS

Description Specification
Height of Cylinder Head (1), With Out Camshaft 126.85mm to 127.15mm
Housing
Valve Set Back (2) With New Valves and New Exhaust Valve: 1.0mm - 1.4mm
Valve Seat Rings
- Intake Valve: 1.1mm - 1.5mm
REMOVAL
CYLINDER HEAD

1. Disconnect negative battery (1) cable located under passenger seat.

2. Raise and support vehicle.
Fig. 55: Engine Compartment Lower Silencer

3. Remove engine compartment lower silencer (1) and drive belt splash shield (2). See Fig. 55 .
WARNING: RISK OF INJURY TO SKIN AND EYES FROM SCALDING COOLANT.

DO NOT OPEN COOLING SYSTEM UNLESS TEMPERATURE IS
BELOW 90°C (194°F). OPEN CAP SLOWLY TO RELEASE

PRESSURE. STORE COOLANT IN APPROVED CONTAINER ONLY.
WEAR PROTECTIVE GLOVES, CLOTHING AND EYE WEAR.
Fig. 56: Turbo Support Bracket

5. Disconnect exhaust pipe from turbocharger downpipe.

6. Remove exhaust manifold support bracket (2).
7. Remove turbocharger support bracket (1).
8. Disconnect charge air cooler pipe from turbocharger.
9. Disconnect oil return line from turbocharger.
10. Remove starter and position out of the way.
11. Remove accessory drive belt.
12. Lower vehicle.
Fig. 57: Intake Manifold


14. Remove radiator closure panel. Refer to Body/Exterior/CROSSMEMBER, Radiator - Removal .
15. Disconnect upper radiator hose from thermostat housing.
16. Pull cooling module forward to gain access to the intake manifold inlet hose (3). Disconnect inlet hose (3)
at manifold.

17. Remove engine cover retaining nuts (1). Pull upwards on cover to remove. See Engine - Removal.
18. Remove air cleaner housing and turbocharger inlet hose. See Fig. 59 . See Engine/Air Intake
System/BODY, Air Cleaner - Removal.
19. Remove coolant recovery pressure container.

20. Disconnect vacuum hose at turbocharger (2) waste gate actuator.
WARNING: NO FIRE, OPEN FLAMES OR SMOKING. RISK OF POISONING FROM

INHALING AND SWALLOWING FUEL. RISK OF INJURY FROM SKIN
AND EYE CONTACT WITH FUEL. POUR FUELS ONLY INTO
SUITABLE AND APPROPRIATELY MARKED CONTAINERS. WEAR
PROTECTIVE CLOTHING WHEN HANDLING FUEL.
Fig. 60: Fuel Injector and Glow Plug Locations

21. Disconnect fuel injector (1), glow plug (2) electrical connectors.
22. Remove fuel high pressure lines (4) , return lines, injectors (1), and fuel rail (3).
23. Reposition wiring harness out of way.
Fig. 61: Cylinder Head Cover - Typical

24. Remove camshaft position sensor (1) electrical connector.

25. Remove cylinder head cover (2). See Engine/Cylinder Head/COVER(S), Cylinder Head - Removal.
Fig. 62: Aligning Timing Mark

NOTE: Rotate engine by the crankshaft bolt in a clockwise direction. DO NOT

rotate the engine using the camshaft sprocket bolt.
NOTE: DO NOT rotate the engine backwards (counter clockwise).
26. Position piston of cylinder #1 to ignition TDC. Markings on the camshaft bearing cap must be
aligned.
Fig. 63: Crankshaft Lock 8933

27. Install Crankshaft Lock 8933 (2) into the engine block (1)
Fig. 64: Special Tool #8929

28. Install Camshaft Locking Pins 8929 (1) into cylinder head and intake camshaft sprocket (2). See Fig. 64.
Fig. 65: Timing Chain Tensioner - Typical

29. Remove right upper engine mount.

30. Remove right engine mount bracket from cylinder head.
31. Mark timing chain and sprockets with paint.
32. Remove timing chain tensioner (1). See Engine/Valve Timing/CHAIN, Timing - Removal.
Fig. 66: Cylinder Head Front Cover - Typical

33. Remove cylinder head front cover (5). See Engine/Cylinder Head - Removal.
34. Remove top guide rail (1). See Engine/Valve Timing/CHAIN, Timing - Removal.
35. Remove high pressure pump. Refer to Fuel System/Fuel Delivery/PUMP, Fuel Injection - Removal .
36. Remove vacuum pump. See Engine/Engine Block/PUMP, Vacuum - Removal.
37. Remove camshafts. See Engine/Cylinder Head/CAMSHAFT, Engine - Removal.
Fig. 67: Intermediate Gear

38. Remove intermediate gear (5). See Engine/Valve Timing/CHAIN, Timing - Removal.
39. Unbolt oil dip stick tube, ground, and electrical connectors from cylinder head.
40. Disconnect EGR valve to mixing chamber pipe at EGR valve.
41. Remove upper timing case to cylinder head bolts.
NOTE: Loosen cylinder head bolts in the reverse order of the tightening
sequence. See Fig. 68.
Fig. 68: Cylinder Head Bolt Torque Sequence

42. Remove cylinder head bolts in reverse order of the tightening sequence and inspect bolts. See Fig. 68. See
Engine/Cylinder Head - Standard Procedure.
43. Remove cylinder head assembly from engine.
44. Disassemble cylinder head assembly as necessary for service.
CYLINDER HEAD FRONT COVER

1 - BATTERY
2 - PASSENGER SEAT


2 - ENGINE COVER

1 - TOP GUIDE RAIL

2 - CYLINDER HEAD COVER
3 - LOCKING PAWL
4 - DOWEL PIN
5 - CYLINDER HEAD FRONT COVER
6 - SEAL
7 - TIMING CHAIN TENSIONER
4. Remove timing chain tensioner (7). See Engine/Valve Timing/TENSIONER, Engine Timing -
Removal.
5. Remove bolts attaching front cover (5).
NOTE: Lower portion of front cover is sealed with RTV sealant. Carefully tug at
front cover until it loosens from cylinder head.
6. Raise locking pawl (3) of top guide rail (1) and remove cylinder head front cover (5). See Fig. 71. .
NOTE: Dowel pins are use as a guide during assembly and must remain in the
proper position to assure a good sealing surface.
CYLINDER HEAD GUIDE RAIL

1 - BATTERY
2 - PASSENGER SEAT


2 - ENGINE COVER
CAUTION: Rotate engine at crankshaft only. DO NOT rotate the engine with the
bolt of the camshaft sprocket. DO NOT rotate the engine back.
NOTE: Markings on the camshaft and camshaft bearing cap must be aligned.

1 - TOP GUIDE RAIL

3 - LOCKING PAWL
4 - DOWEL PIN
6 - SEAL
5. Carefully raise locking pawl (3) of top slide rail (1) and remove cylinder head front cover (5) . See Fig.
74 and see Engine/Cylinder Head - Removal.
Fig. 75: Camshaft Locking Pin 8929

1 - CAMSHAFT LOCKING PIN 8929

2 - INTAKE CAMSHAFT SPROCKET
3 - INTERMEDIATE GEAR COVER
6. Insert Camshaft Locking Pin 8929 through 1st camshaft bearing cap into the hole in the intake camshaft
sprocket (2).
7. Counter hold the camshaft with an open end wrench to avoid damage and unbolt driver of inlet camshaft
sprocket.

1 - TOP GUIDE RAIL

3 - LOCKING PAWL
4 - DOWEL PIN
6 - SEAL
8. Remove top guide rail (1).
CLEANING
CLEANING
To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of
aluminum engine components and multi-layer steel cylinder head gaskets.
NOTE: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.
Remove all gasket material from cylinder head and block. See Engine - Standard Procedure. Be careful not to
gouge or scratch the aluminum head sealing surface.
Clean all engine oil passages.
INSTALLATION
CYLINDER HEAD
WARNING: NO FIRE, OPEN FLAMES OR SMOKING. SERVICE VEHICLES IN WELL

VENTILATED AREAS. RISK OF POISONING FROM INHALING OR
SWALLOWING FUEL. RISK OF INJURY FROM SKIN AND EYE CONTACT
WITH FUEL. WEAR PROTECTIVE CLOTHING.
NOTE: Thoroughly clean all mating surfaces with appropriate solvents and blow out
bolt holes, to assure that no grease or oil is present during reassembly.
NOTE: If piston or connecting rods have been replaced, measure piston projection.
NOTE: Check facing cylinder head contact surface.
Fig. 77: Cylinder Head Bolt Torque Sequence

1. Position the cylinder head and gasket properly on engine using the dowel pins as guide.
NOTE: Inspect all cylinder head bolts for defects and stretching before
installation. See Engine/Cylinder Head - Standard Procedure.
The M12 cylinder head bolts must be torqued in 3 stages.
2. Install cylinder head assembly on engine block.
3. Install M12 cylinder head bolts finger tight.

4. Torque bolts in numeric order starting with number 1 to 60 N.m (44 lbs. in.). See Fig. 77.
5. Install M8 timing chain cover to cylinder head bolts. Tighten to 20N.m (177 lbs. in.).
6. Tighten M12 cylinder head bolts in numeric order starting with number 1 an additional 90°. See Fig. 77.

1 - INTAKE MANIFOLD
2 - INTAKE MANIFOLD RETAINING BOLTS
3 - INTAKE INLET HOSE
7. Connect vacuum hose at turbocharger waste gate solenoid.

8. Connect intake manifold inlet tube (3) at intake manifold (1).
9. Connect EGR valve to mixing chamber pipe at EGR valve.
10. Connect oil dip stick tube. Tighten to 14 N.m (124 lbs. in.).

1 - CAMSHAFT SPROCKET BOLTS

2 - INTAKE CAMSHAFT
3 - DOWEL PIN
4 - INTERMEDIATE GEAR BUSHING
5 - INTERMEDIATE GEAR
6 - CAMSHAFT LOCKING PIN
11. Install intermediate timing chain gear (5). See Engine/Valve Timing/CHAIN, Timing - Installation.
12. Install camshafts. See Engine/Cylinder Head/CAMSHAFT, Engine - Installation.
13. Install vacuum pump. See Engine/Engine Block/PUMP, Vacuum - Installation.
14. Install high pressure pump. Refer to Fuel System/Fuel Delivery/PUMP, Fuel Injection - Installation .

1 - TOP GUIDE RAIL

3 - LOCKING PAWL
4 - DOWEL PIN
6 - SEAL
15. Install cylinder head front cover (5) and top guide rail (1). See Engine/Cylinder Head - Installation.
Fig. 81: TIMING CHAIN TENSIONER - TYPICAL


2 - TIMING CHAIN TENSIONER SEAL
16. Install timing chain tensioner (1) with new seal (2). See Engine/Valve Timing/CHAIN, Timing -
Installation. Tighten to 80N.m (59 lbs. ft.).
Fig. 82: Special Tool #8929

17. Remove Camshaft Locking Pin 8929 (1).

1 - CAMSHAFT POSITION (CMP) SENSOR

3 - CYLINDER HEAD COVER GASKET
4 - INJECTOR BORE SEALS
18. Install cylinder head cover (2). See Engine/Cylinder Head/COVER(S), Cylinder Head - Installation.
19. camshaft position sensor connector (1).

1 - FUEL INJECTORS
2 - GLOW PLUGS
3 - FUEL RAIL
4 - HIGH PRESSURE FUEL LINE
20. Reposition engine electrical harness and connect the fuel injector (1), glow plug (2), and coolant
temperature electrical connectors.
Fig. 85: FUEL INJECTOR REMOVAL/INSTALLATION - TYPICAL

1 - INJECTOR DRAIN TUBES

2 - RETAINING CLIP
3 - INJECTOR HIGH PRESSURE LINE
4 - INJECTOR SEAL
5 - FUEL INJECTOR
6 - TENSIONING CLAW
7 - SPECIAL TOOLS #8938 AND #8937
21. Install fuel injectors (5) and high pressure lines (3).
Fig. 86: Turbo Support Bracket

22. Raise vehicle on hoist.

23. Install turbocharger support bracket (1). Tighten bolts to 30N.m (22 lbs. ft.).
24. Install oil return flow line at turbocharger.
25. Remove Crankshaft Lock 8933 (2).

26. Install starter.
27. Install charge air distribution pipe.

28. Install engine compartment lower silencer (1) and accessory drive belt splash shield (2).
29. Lower vehicle.


3 - MAF SENSOR
4 - O-RING
7 - INLET DUCT
30. Install air cleaner housing (6) and turbocharger air intake hose (1).
31. Install coolant recovery pressure container.
32. Connect upper radiator hose to thermostat housing.
33. Install radiator closure panel. Refer to Body/Exterior/CROSSMEMBER, Radiator - Installation .
Fig. 90: GRILL REMOVAL

34. Install front grille assembly (2). Refer to Body/Exterior/GRILLE - Installation .

35. Refill cooling system with proper coolant mixture to proper level. Refer to SYSTEM FILLING -
DIESEL ENGINE .

36. Connect negative battery (1) cable located under passenger seat.

37. Start engine and inspect for leaks.

CYLINDER HEAD FRONT COVER
Fig. 93: Cylinder Head Cover Sealing Surface


2 - SEALANT BEAD
NOTE: Thoroughly clean all mating surfaces with appropriate solvents to assure that
no grease or oil is present during reassembly.
NOTE: Dowel pins are used as a guide during assembly and must remain in the proper
position to assure a good sealing surface.
1. Apply sealant to the marked surfaces with a bead thickness of 1.5 ± 0.5 mm. See Fig. 93.
NOTE: Install front cover of cylinder head within 10 minutes after applying
sealant. Do not spread sealing bead.

1 - TOP GUIDE RAIL

3 - LOCKING PAWL
4 - DOWEL PIN
6 - SEAL
2. Raise locking pawl (3) of top guide rail and guide front cover (5) onto guide pins.
3. Install bolts attaching front cover (5). See Fig. 94. Tighten bolts to 14N.m (124 lbs. in.).
NOTE: Timing chain tensioner must be installed with a new seal.
4. Install timing chain tensioner (7) and new seal (6). See Engine/Valve Timing/CHAIN, Timing -
Installation.

1 - BATTERY
2 - PASSENGER SEAT
WARNING: Use extreme caution when the engine is operating. Do not stand in a
direct line with the fan. Do not put your hands near the pulleys, belts
or fan. Do not wear loose clothes.
6. Start the engine and inspect for leaks.


2 - ENGINE COVER
CYLINDER HEAD GUIDE RAIL

1 - TOP GUIDE RAIL

3 - LOCKING PAWL
4 - DOWEL PIN
6 - SEAL
1. Carefully position the top guide rail (1) onto the dowel pins (4).
2. Counter hold the camshaft with an open end wrench and install driver of inlet camshaft sprocket. Tight
bolt to 50N.m (37 lbs. ft.).
3. Carefully raise locking pawl (3) of top guide rail (1) and install cylinder head front cover . See Fig. 97.
See Engine/Cylinder Head - Installation.
Installation.

1 - BATTERY
2 - PASSENGER SEAT
6. Reconnect negative battery (1) cable.


2 - ENGINE COVER
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO

NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHES.

CAMSHAFT, ENGINE
Standard Procedure
CHECKING CAMSHAFT POSITION

1 - BATTERY
2 - PASSENGER SEAT
1. Disconnect negative battery (1) cable.

WARNING: No fire, sparks, or smoking. Risk of poisoning from inhaling and

swallowing fuel as well as risk of injury to eyes and skin from
contact with fuel. Pour fuel only into suitable and marked containers.
Wear protective clothing when handling fuel.

4. Clean injectors and recesses. Refer to Fuel System/Fuel Injection/INJECTOR(S), Fuel - Standard
Procedure .

1 - TOP GUIDE RAIL

3 - LOCKING PAWL
4 - DOWEL PIN
6 - SEAL
NOTE: Rotate engine at crankshaft only. DO NOT crank engine at the camshaft
and DO NOT rotate the engine backward.
Fig. 102: Checking Camshaft Position - Typical

1 - CAMSHAFT SPROCKET ALIGNMENT DOTS

2 - CAMSHAFT LOCK POSITION
4 - CAMSHAFT AND BEARING CAP ALIGNMENT
MARKS

6. Position piston of cylinder #1 to ignition TDC.

7. Insert the Camshaft Locking Pin 8929 (5) through first camshaft bearing cap into the hole in the left inlet
camshaft sprocket. See Fig. 102.
NOTE: The two markings in the inlet camshaft sprockets (1) must be positioned
opposite and markings of camshaft and camshaft bearing cap must be
aligned. If not, perform basic position of camshafts.
8. Remove Camshaft Locking Pin 8929 (5) from camshaft bearing cap hole.

1 - TOP GUIDE RAIL

3 - LOCKING PAWL
4 - DOWEL PIN
6 - SEAL
10. Install injectors. Refer to Fuel System/Fuel Injection/INJECTOR(S), Fuel - Installation .
or fan. Do no wear loose clothing.

12. Install engine cover.
Removal
REMOVAL

1 - BATTERY
2 - PASSENGER SEAT
1. Disconnect negative battery (1) cable located under the passenger seat.
WARNING: No fire, open flames or smoking. Risk of poisoning from inhaling or

swallowing fuel. Risk of injury from skin and eye contact with fuel.
Wear protective clothing. Store fuel only in suitable and
appropriately marked containers.


2 - RETAINING CLIP
4 - INJECTOR SEAL
5 - FUEL INJECTOR
6 - TENSIONING CLAW
3. Remove high pressure lines (3) and injectors (5). Refer to Fuel System/Fuel Injection/INJECTOR(S),
Fuel - Removal .
4. Remove cylinder head cover. See Engine/Cylinder Head/COVER(S), Cylinder Head - Removal.
Fig. 106: Camshaft Alignment - Typical

1 - EXHAUST CAMSHAFT SPROCKET AND CHAIN

MARKING
2 - EXHAUST CAMSHAFT SPROCKET BOLTS
3 - EXHAUST CAMSHAFT SPROCKET
4 - CAMSHAFT ALIGNMENT DOTS
5 - INTAKE CAMSHAFT LOCK POSITION
5. Position piston of cylinder #1 to ignition TDC. See Fig. 106.
Fig. 107: Special Tool 8929-Camshaft Locking Pin


6. Install Camshaft Locking Pin 8929 (1). See Fig. 107.

7. Remove starter and position out of the way.
8. Install Crankshaft Lock 8933.

1 - TOP GUIDE RAIL

3 - LOCKING PAWL
4 - DOWEL PIN
6 - SEAL
NOTE: The lower portion of the cylinder head front cover is sealed with RTV
sealant. Carefully tug front cover after bolt removal to loosen from cylinder
head.
11. Remove top side rail (1). See Engine/Cylinder Head - Removal.
Fig. 109: Camshafts and Housing Assembly - Typical

1 - CYLINDER HEAD BOLTS

2 - EXHAUST CAMSHAFT
3 - INTAKE CAMSHAFT
4 - CAMSHAFT HOUSING
5 - CYLINDER HEAD
CAUTION: For all work in which the crankshaft should not rotate, secure
camshaft gear to timing chain.
12. Mark camshaft sprocket relative to timing chain.

13. Unbolt camshaft sprocket from exhaust camshaft (2).
NOTE: Note the position of dowel pin for camshaft sprocket alignment during
reassembly.
14. Remove camshaft sprocket.
CAUTION: Camshaft bearing caps must remain in proper order and position.
15. Mark and remove camshaft bearing caps.

16. Remove the inlet and exhaust camshafts. See Fig. 109. .
Installation
INSTALLATION
CAUTION: The camshafts are sensitive to fracturing. Ensure they are installed free of
stress.
CAUTION: Pay attention to assignment of camshafts. Camshaft code numbers are

visible on the thrust collar of the axial bearing.
CAUTION: Oil bucket tappets and camshaft bearing points. Inspect ease of operation
of bucket tappets.
Fig. 110: Camshafts and Housing Assembly - Typical
1 - CYLINDER HEAD BOLTS

2 - EXHAUST CAMSHAFT
3 - INTAKE CAMSHAFT
4 - CAMSHAFT HOUSING
5 - CYLINDER HEAD
1. Install inlet (3) and exhaust (2) camshafts.
CAUTION: Install camshafts so that the two holes in camshaft sprockets are
positioned opposite and the markings of the camshaft and camshaft
bearing cap are aligned.
2. Align inlet (3) and exhaust (2) camshafts at axial bearing. See Engine/Cylinder Head/CAMSHAFT,
Engine - Standard Procedure).
3. Position piston of cylinder #1 to 30° TDC.
NOTE: Pay attention to markings on camshaft bearing caps.
4. Install camshaft bearing caps in the proper order. Tighten bolts to 9N.m (80 lbs. in.).


MARKING
CAUTION: Do not rotate engine counter clockwise.
5. Position the piston of cylinder #1 to ignition TDC.
NOTE: Pay attention to markings on camshaft bearing caps.
6. Install the bearing caps in reverse order at the same point. Tighten bearing cap bolts evenly in steps each
of 1 turn.
NOTE: The piston of cylinder #1 must be positioned at ignition TDC when the inlet
camshaft is locked.
7. Insert Camshaft Locking Pin 8929 (7) in through the first camshaft bearing cap into the whole in the
camshaft sprocket.
NOTE: Do Not use old camshaft sprocket bolts.
8. Fit exhaust camshaft sprocket with timing chain (1) onto exhaust camshaft paying attention to position of
dowel pin. Tighten bolt to 18N.m (159 lbs. in.).


Installation.


MARKING

10. Inspect/Set basic position of camshafts. See Engine/Cylinder Head/CAMSHAFT, Engine - Standard
Procedure).
11. Remove Crankshaft Lock 8933.
12. Install starter.
13. Remove Camshaft Locking Pin 8929(7).

1 - TOP GUIDE RAIL

3 - LOCKING PAWL
4 - DOWEL PIN
6 - SEAL
NOTE: Refer to the appropriate injector servicing procedures for cleaning of

injectors and recesses.
15. Clean and install injectors. Refer to Fuel System/Fuel Injection/INJECTOR(S), Fuel - Standard
Procedure . Refer to Fuel System/Fuel Injection/INJECTOR(S), Fuel - Installation .

1 - BATTERY
2 - PASSENGER SEAT
16. Connect negative battery (1) cable.
or fan. Do not wear loose clothing.


2 - ENGINE COVER
COVER(S), CYLINDER HEAD
Removal
REMOVAL

1 - BATTERY
2 - PASSENGER SEAT


2 - ENGINE COVER

1 - FUEL INJECTORS
2 - GLOW PLUGS
3 - FUEL RAIL
3. Remove high pressure fuel lines (4) to fuel injectors (1). See Fig. 119.
4. Disconnect fuel injector (1), camshaft position sensor, fuel pressor sensor, fuel pressure solenoid, and
glow plug (2) electrical connectors.


2 - RETAINING CLIP
4 - INJECTOR SEAL
5 - FUEL INJECTOR
6 - TENSIONING CLAW
5. Disconnect injector drain tubes (1) at injectors (5).

6. Disconnect fuel rail return line to pump at rail.
7. Remove engine harness retaining bolts and reposition harness out of way.
8. Remove fuel injectors (5). Refer to Fuel System/Fuel Injection/INJECTOR(S), Fuel - Removal .

1 - CAMSHAFT POSITION (CMP) SENSOR

9. Detach hose from oil separator.

10. Remove cylinder head cover retaining bolts and remove cover (2). See Fig. 121.
Installation
INSTALLATION
Fig. 122: Cylinder Head Cover Gasket and Seal Location


1. Install new gasket (2) and injector bore seals (3) on cylinder head cover (1). See Fig. 122.
NOTE: Do not tighten cylinder head cover bolts until injectors are installed.
2. Position cylinder head cover with new gasket and seals. Tighten bolts only finger tight.


2 - RETAINING CLIP
4 - INJECTOR SEAL
5 - FUEL INJECTOR
6 - TENSIONING CLAW
3. Install injectors (5) into cylinder head. Refer to Fuel System/Fuel Injection/INJECTOR(S), Fuel -
Installation .
4. Torque cylinder head cover bolts to 9N.m (80 lbs. in.).
5. Reroute engine harness and install retaining bolts.
6. Install injector high pressure fuel lines (3).
7. Torque injector retaining bolts to 7N.m (62 lbs. in.) + 90°.

1 - FUEL INJECTORS
2 - GLOW PLUGS
3 - FUEL RAIL
8. Connect fuel injector (1), camshaft position sensor, fuel pressure sensor, fuel pressure solenoid, and glow
plug (2) electrical connectors.


2 - RETAINING CLIP
4 - INJECTOR SEAL
5 - FUEL INJECTOR
6 - TENSIONING CLAW
9. Connect fuel drain tubes (1) at injectors.

10. Attach oil separator hose.

WARNING: USE EXTREME CAUTION WHEN ENGINE IS OPERATING. DO NOT

STAND IN A DIRECT LINE WITH FAN. DO NOT PUT YOUR HANDS
NEAR PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHES.

SPRING(S), VALVE
Removal
VALVE SPRINGS

1 - BATTERY
2 - PASSENGER SEAT


2 - ENGINE COVER


1 - TOP GUIDE RAIL

3 - LOCKING PAWL
4 - DOWEL PIN
6 - SEAL
6. Remove front cover at cylinder head (5). See Engine/Cylinder Head - Removal.
7. Remove top guide rail (1). See Engine/Cylinder Head - Removal.
8. Remove camshafts. See Engine/Cylinder Head/CAMSHAFT, Engine - Removal.
NOTE: The timing chain must be held in up position so as not to jam during
procedure.
9. Position piston of cylinder to be processed to TDC by rotating the crankshaft clockwise. DO NOT crank
engine. DO NOT rotate engine backward.

1 - ENGINE BLOCK
2 - CRANKSHAFT LOCK 8933
10. Install Crankshaft Lock 8933.

11. install special tool #9543 into injector hole and retain with original tensioning claw.
12. Connect air supply to adapter and pressurize the cylinder to 5 bar (73 psi).
WARNING: Valve springs and retainers must be kept in order of the cylinder
they were removed.
NOTE: Using tool, screw retaining fork into threaded edge of cylinder head and
position thrust piece vertically at top of valve spring retainer.
Fig. 131: VALVE COMPRESSOR

1 - VALVE ASSEMBLY TOOL

2 - VALVE KEEPERS
3 - MAGNET
13. Compress valve spring.

14. Remove valve keepers (2).
15. Remove valve spring retainer and valve spring.
16. Remove valve stem seals.
17. Remove valve spring seat.
NOTE: Inspect all cylinder head components for wear or damage.
18. Repeat procedure for each cylinder as necessary.
VALVES

1 - BATTERY
2 - PASSENGER SEAT


2 - ENGINE COVER
2. Remove engine cover (2). See Engine - Removal

3. Remove cylinder head. See Engine/Cylinder Head - Removal.
CAUTION: Suitably mark the valve and the position in the cylinder head before
removal. Failure to do so will result in improperly seated valves and
possible engine damage after reassembly.
position thrust piece vertically at top of valve spring retainer.
Fig. 134: VALVE ASSEMBLY

1 - VALVE
2 - VALVE SPRING SEAT
3 - VALVE STEM SEAL
4 - VALVE SPRING
5 - VALVE SPRING RETAINER
6 - VALVE KEEPERS
7 - CYLINDER HEAD
4. Using a suitable valve spring compressor, compress valve spring.

5. Remove valve keepers (2).
6. Remove valve spring retainer (5) and valve spring (4).
7. Remove valve stem seals (3).
8. Repeat steps 5 through 9 for each valve as necessary.
CAUTION: Valves, springs and retainers must be kept in order of the cylinder
they were removed.
9. Remove valves (1).
Installation
VALVE SPRINGS

1 - VALVE
3 - VALVE STEM SEAL
4 - VALVE SPRING

6 - VALVE KEEPERS
7 - CYLINDER HEAD
NOTE: Inspect all valve springs and retainers for wear or damage. Replace as
necessary.
1. Position piston of cylinder to be processed to TDC by rotating the crankshaft clockwise. DO NOT crank
engine or rotate engine counter clockwise.
2. Connect air supply to #9543 adaptor and pressurize the cylinder to 5 bar (73 psi).
3. Install lower valve spring seat (2).
4. Install valve stem seal (3).
5. Install valve spring (4).
6. Install valve spring retainer (5).
position thrust piece vertically at the top of each valve spring retainer.
NOTE: Ensure that the valve keepers are seated properly.
Fig. 136: VALVE COMPRESSOR

1 - VALVE ASSEMBLY TOOL

2 - VALVE KEEPERS
3 - MAGNET
7. Compress valve and install valve keepers (2).

8. Repeat procedure for each cylinder as necessary.
9. Remove special tooling from cylinder head.

1 - TOP GUIDE RAIL

3 - LOCKING PAWL
4 - DOWEL PIN
6 - SEAL
10. Position piston of #1 cylinder to ignition TDC.

11. Install camshafts and check basic position. See Engine/Cylinder Head/CAMSHAFT, Engine -
Installation.
12. Install top guide rail (1). See Engine/Cylinder Head - Installation.
13. Install front cover (5) at cylinder head. See Engine/Cylinder Head - Installation.
Installation.
WARNING: Service vehicles in a well ventilated area and avoid ignition sources.
Risk of injury to skin and eyes from fuel jet flowing out.


2 - RETAINING CLIP
4 - INJECTOR SEAL
5 - FUEL INJECTOR
6 - TENSIONING CLAW
16. Install injectors (5). Refer to Fuel System/Fuel Injection/INJECTOR(S), Fuel - Installation .

1 - BATTERY
2 - PASSENGER SEAT
17. Reconnect negative battery (1) cable.
or fan. Do not wear loose clothing.


2 - ENGINE COVER
VALVES

1 - VALVE
3 - VALVE STEM SEAL
4 - VALVE SPRING
6 - VALVE KEEPERS
7 - CYLINDER HEAD
CAUTION: Valves must be kept in their original positions in cylinder head. Failure to
do so will result in engine damage.
NOTE: Inspect all valves, springs and retainers for wear or damage. Replace as
necessary.
1. Install valves (1) in their original position in the cylinder head (7).
2. Install valve spring seat (2).
3. Install valve stem seal (3).
4. Install valve spring (4).
5. Install valve spring retainer (5).

1 - VALVE
3 - VALVE STEM SEAL
4 - VALVE SPRING
6 - VALVE KEEPERS
7 - CYLINDER HEAD
NOTE: Ensure that the valve keepers are seated properly.
6. Using a suitable valve spring compressor, compress valve spring (4) and install valve keepers (6).
7. Repeat steps 3 through 7 for each valve as necessary.
8. Install cylinder head on engine block. See Engine/Cylinder Head - Installation.
9. Install glow plugs. Refer to Electrical/Ignition Control/PLUG, Glow - Installation .

1 - BATTERY
2 - PASSENGER SEAT
WARNING: Use extreme caution when the engine is in operation. Do not stand
in a direct line with the fan. Do not put your hands near the pulleys,
belts or fan. Do not wear loose clothing.
11. Start engine and check for leaks.


2 - ENGINE COVER
ENGINE BLOCK
STANDARD PROCEDURE
REPLACING ENGINE CORE AND OIL GALLERY PLUGS
Fig. 145: Core Hole Plug Removal

1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
4 - DRIFT PUNCH
5 - CUP PLUG
Using a blunt tool such as a drift (4) and a hammer, strike the bottom edge of the cup plug (5). With the cup
plug (5) rotated, grasp firmly with pliers (2) or other suitable tool and remove plug. See Fig. 145. .
CAUTION: Do not drive cup plug into the casting as restricted cooling can result and
cause serious engine problems.
Thoroughly clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer. Lightly coat
inside of cup plug hole with Mopar® Stud and Bearing Mount. Make certain the new plug is cleaned of all oil
or grease. Using proper drive plug, drive plug into hole so that the sharp edge of the plug is at least 0.5 mm
(0.020 in.) inside the lead-in chamfer.
It is not necessary to wait for curing of the sealant. The cooling system can be refilled and the vehicle placed in
service immediately.
MEASURING CYLINDER BORES
Fig. 146: Measuring Cylinder Bores

1 - MEASURING POINT OF CYLINDER BORE

1a - UPPER REVERSAL POINT OF #1 PISTON RING
1b - BOTTOM DEAD CENTER OF PISTON
1c - BOTTOM REVERSAL POINT OF OIL SCRAPER RING
1A - LONGITUDINAL DIRECTION
1B - TRANSVERSE DIRECTION
NOTE: This must be done with engine completely disassembled.
1. Thoroughly clean all cylinder bores with appropriate cleaning solvent.

2. Measure each cylinder at the three measuring points shown (1 ,2, 3). See Fig. 146.
3. Using the three measurement points, measure cylinder in the longitudinal and in the transverse direction.
See Fig. 146.
Standard size 88.0 mm

Group code letter A 88.000-88.006 mm
Group code letter X 88.006-88.012 mm
Group code letter B 88.012-88.018 mm
Wear limit in longitudinal in 0.020 mm
transverse direction
Permissible variation of 0.000-0.014 mm
cylinder shape (when new)
4. Use the measurement and table above to group cylinder bores.
CRANKSHAFT
Standard Procedure
MEASURE CRANKSHAFT AND BLOCK JOURNALS
Fig. 147: Checking Crankshaft End Play - Typical

NOTE: After any bearing damage occurred, remove all debris which is present in the
main oil gallery, connecting rod bores, and in the crankshaft and oil galleries.
Include removal of the inserting steel ball of the main oil gallery before
cleaning.
1. Using a dial indicator (2) check crankshaft (1) end play by moving the crankshaft back and forth in the
appropriate direction. See Fig. 147.
2. Remove crankshaft. See Engine/Engine Block/CRANKSHAFT - Removal.
3. Clean all engine parts thoroughly.
CAUTION: After bearing has damage has occurred, replace connecting rods
which have suffered overheating because of bearing damage. The
connecting rod must not have any cross scores and notches.
Fig. 148: Crankshaft Journal Measurements - Typical

4. Inspect connecting rod. If damage is present, inspect crankshaft, replace as necessary.

5. Inspect crankcase.
6. Inspect standard size of crankshaft bearing shells.
7. Inspect crankshaft bearing cap.
8. Measure crankshaft rod and main bearing journals with a micrometer. See Fig. 148.
NOTE: Radial mounting of the main bearings of standard size crankshaft is

possible by assigning the color-coded bearing shells.
Fig. 149: Chisel Punch Marks
ASSIGN CRANKSHAFT BEARING SHELLS
Fig. 150: Chisel Punch Marks

The oil pan rail of the cylinder block is marked with chisel punches indicating what bearing shell are
used.
9. Assign crankshaft bearing shells.

10. Mount crankshaft axially.
11. Inspect crankshaft bearing play.
Removal
REMOVAL


2 - ENGINE COVER
NOTE: The engine must be removed from the vehicle to service crankshaft.

3. Remove engine. See Engine - Removal.
4. Remove timing chain cover. See Engine/Valve Timing/COVER(S), Engine Timing - Removal.
Fig. 152: Rear Crankshaft Seal/Adapter

1 - FLYWHEEL
2 - FLYWHEEL BOLTS
3 - SPECIAL TOOL #8944
4 - REAR CRANKSHAFT OIL SEAL
5 - REAR CRANKSHAFT SEAL ADAPTER
6 - CRANKSHAFT
7 - ALIGNMENT DOWELS
8 - REAR CRANKSHAFT SEAL ADAPTER RETAINING
BOLT
9 - OIL PAN TO REAR CRANKSHAFT SEAL ADAPTER
RETAINING BOLT
5. Remove rear crankshaft seal adapter (5). See Engine/Engine Block/SEAL, Crankshaft Oil - Removal.
6. Remove piston and connecting rod assemblies. Refer to Engine/Engine Block/ROD, Piston and
Connecting - Removal .
Fig. 153: Crankshaft Assembly - Typical

CAUTION: The crankshaft main bearing caps (5) are numbered consecutively,
beginning with the first crankshaft bearing cap at the front of engine.
Attention must be paid to the way crankshaft bearing caps fit.
7. Unbolt crankshaft main bearing caps (5). See 6 .

8. Inspect crankshaft bearing caps (5) and bolts (7) for wear and stretching.
9. Remove crankshaft (3) from engine block.
Installation
INSTALLATION
Fig. 154: CYLINDER BLOCK MARKINGS - TYPICAL

NOTE: The cylinder block is marked for main bearing shell selection.
CAUTION: Oil bearing shells before inserting crankshaft.
CAUTION: Oil grooves in thrust washers must point toward the thrust collars of the
crankshaft.
CAUTION: Thrust washers in bearing cap each have two retaining lugs as a anti-twist
lock.
CAUTION: Oil thread and head contact surfaces of bolts that retain crankshaft
bearing caps; tighten bolts from inside to outside, beginning at fit bearing.
Rotate crankshaft to check clearance.
CAUTION: The crankshaft bearing caps are numbered consecutively, beginning with
the first crankshaft bearing cap at the front of engine. Attention must be
paid to the way crankshaft bearing caps fit.
Fig. 155: Crankshaft Assembly - Typical

1. Install bearing halves into engine block (1).

2. Install crankshaft (3) into engine block.
3. Install bearing halves into bearing caps (4).
4. Install crankshaft main bearing caps (5). Tighten bolts in two stages. 55N.m (40.5 lbs ft), then 90°.
5. Install piston and connecting rod assemblies. Refer to Engine/Engine Block/ROD, Piston and
Connecting - Installation .

6. Install rear crankshaft seal adapter (5). See Engine/Engine Block/SEAL, Crankshaft Oil - Installation.
7. Install timing chain cover. See Engine/Valve Timing/COVER(S), Engine Timing - Installation.
8. Install the engine. See Engine - Installation.
9. Fill crankcase with the correct engine oil, to the proper level. Refer to the owner's manual for
specifications.
10. Fill cooling system with the proper coolant, to the proper level. Refer to SYSTEM FILLING - DIESEL
ENGINE .


2 - ENGINE COVER
direct line with the fan. Do not put your hands near the pulleys,
belts, or fan. Do not wear loose clothes.

FLEXPLATE
Removal
REMOVAL
Fig. 158: FLEX PLATE

1. Remove transaxle. Refer to Transmission and Transfer Case/Manual - Removal .

2. Remove flex plate retaining bolts (1).
3. Remove flex plate (2).
Installation
INSTALLATION
Fig. 159: FLEX PLATE

1. Install flex plate (2).

2. Install flex plate retaining bolts (1). Torque bolts to 45N.m (33 lbs. ft.) then 90°.
3. Install transaxle. Refer to Transmission and Transfer Case/Manual - Removal .
MODULE, BALANCE SHAFT
Description
DESCRIPTION
Fig. 160: Balance Shaft Location

1 - CRANKSHAFT
2 - ENGINE BLOCK
3 - BALANCE SHAFT ASSEMBLY
4 - TRANSMISSION BELL HOUSING
5 - RETAINING BOLTS
The 2.2L engine is equipped with two nodular cast iron balance shafts installed in a cast iron carrier attached to
the lower cylinder block. See Fig. 160 .
Operation
OPERATION
The balance shafts are driven by the crankshaft via a roller chain and sprockets. The balance shafts are
connected by helical gears. The dual counter rotating shafts decrease second order vertical shaking forces
caused by component movement.
Removal
REMOVAL


3. Remove engine compartment lower silencer (1) and accessory drive belt splash shield (2). See Fig. 161 .
4. Drain engine oil.
5. Remove oil pan. See Engine/Lubrication/PAN, Oil - Removal.

1 - CRANKSHAFT
2 - ENGINE BLOCK
5 - RETAINING BOLTS
6. Remove balance shaft retaining bolts (5) and remove balance shaft assembly (3) from engine block (2).
See Fig. 162 .
Installation
INSTALLATION
Before the balance shaft assembly can be installed, the balance shaft shim thickness must be determined. Follow
steps below to determine shim thickness.
DETERMINING BALANCE SHAFT SHIM THICKNESS
Fig. 163: Measurements for Determining Shim Thickness

1 - ENGINE BLOCK
2 - CRANKSHAFT POSITION DURING MEASUREMENT
3 - DIMENSION B
4 - CRANKSHAFT
5 - BALANCE SHAFT SPROCKET
6 - DIMENSION A
8 - 2.5MM TEST BALL LOCATION
9 - 2.5MM TEST BALL LOCATION
1. Measure and determine dimensions A (6) and B (3) by measuring in the center of the gears. See Fig. 163 .
Measure 4 times approximately 90° apart. Determine mean of the 4 measurements.
Fig. 164: Balance Shaft Shim Thickness Chart

2. After measuring dimension A and B, use the balance shaft shim thickness chart to determine shims
needed for balance shaft assembly. See Fig. 164 .
Fig. 165: Balance Shaft Shim Position

1 - BALANCE SHAFT SHIM

2 - BALANCE SHAFT SHIM
After selecting proper balance shaft shims. Install shims (1,2) on balance shaft assembly (3). See Fig.
165.
Fig. 166: Balance Shaft Position Before Installation


2 - DRILL HOLES IN END OF BALANCE SHAFTS
3 - ASSEMBLY POINT OF CARRIER HALVES
3. Position #1 cylinder at Top Dead Center.

4. Align drill holes (2) at end of balance shafts with assembly point of carrier halves (3). See Fig. 166 .

1 - CRANKSHAFT
2 - ENGINE BLOCK
5 - RETAINING BOLTS
5. Position balance shaft assembly (3) on engine block (2) and install retaining bolts (5). Tighten bolts to
25N.m, then to 45N.m.
6. Install oil pan. See Engine/Lubrication/PAN, Oil - Installation.

1 - ENGINE COMPARTMENT SILENCER

2 - ACCESSORY DRIVE BELT SPLASH SHIELD
7. Install engine compartment lower silencer (1) and accessory drive belt splash shield (2). See Fig. 168 .
8. Lower vehicle.
9. Refill engine oil and power steering fluid to proper specifications.
PUMP, VACUUM
Description
DESCRIPTION
Fig. 169: Vacuum Pump Location

1 - VACUUM PUMP
3 - INJECTION PUMP
The vacuum pump (1) is mounted to the rear of the cylinder head next to the high pressure pump (3) . See Fig.
169. The vacuum pump (1) is of the vane type. The pump supplies vacuum to the brake booster, EGR system,
turbocharger wastegate solenoid, and the swirl valve actuator.
Removal
REMOVAL

1 - VACUUM PUMP
3 - INJECTION PUMP

3. Remove air cleaner housing assembly. See Engine/Air Intake System/BODY, Air Cleaner - Removal.
4. Disconnect vacuum hose from vacuum pump (1).
5. Disconnect the TIPM (2) from bracket and reposition out of way.
6. Remove vacuum pump (1) retaining bolts and remove pump from cylinder head.
Installation
INSTALLATION
Fig. 171: Vacuum Pump O-ring

1 - VACUUM PUMP
2 - O-RING
1. With O-ring (2) installed on vacuum pump (1) , align pump with pump drive on camshaft. See Fig. 171.
2. Slide vacuum pump (1) into cylinder head and install retaining bolts. Torque bolts to 14N.m (124 lbs. in.).

1 - VACUUM PUMP
2 - TIPM
3 - INJECTION PUMP
3. Reposition and connect the TIPM (2) to mounting bracket.

4. Connect vacuum hose to vacuum pump (1).
5. Install air cleaner housing assembly. See Engine/Air Intake System/BODY, Air Cleaner - Installation.
SEAL, CRANKSHAFT OIL, REAR
Removal
REMOVAL

1 - FLYWHEEL
2 - FLYWHEEL BOLTS
6 - CRANKSHAFT
8 - REAR CRANKSHAFT SEAL ADAPTER RETAINING BOLT
9 - OIL PAN TO REAR CRANKSHAFT SEAL ADAPTER RETAINING BOLT
This must be done with the transmission removed from the vehicle.
1. Disconnect the negative battery cable.

2. Raise and support the vehicle.
3. Remove transmission assembly. Refer to Transmission and Transfer Case/Manual - Removal .
4. Drain the engine oil.
NOTE: Loosen all of the oil pan bolts to assure that the oil pan gasket is not
damaged when removing the rear main oil seal and adapter assembly.
NOTE: Inspect the oil pan gasket for damage. If the oil pan gasket is damaged,
remove oil pan and replace oil pan gasket.
5. Loosen oil pan bolts.
6. Remove flywheel (1).
CAUTION: Care must be taken when removing the rear main seal and adaptor
assembly. Failure to do so will result in damage to the oil pan gasket.
7. Remove the rear crankshaft seal adaptor retaining bolts (8) and carefully pry adaptor (5) from crankcase
at adaptor shoulders . See Fig. 173.
Installation
INSTALLATION

1 - FLYWHEEL
2 - FLYWHEEL BOLTS
6 - CRANKSHAFT
8 - REAR CRANKSHAFT SEAL ADAPTER RETAINING BOLT
9 - OIL PAN TO REAR CRANKSHAFT SEAL ADAPTER RETAINING BOLT
NOTE: Thoroughly clean all mating surfaces with the appropriate solvents to assure
that no grease or oil is present during reassembly.
NOTE: Carefully position the rear main seal/adaptor evenly onto the assembly sleeve.
The rear main oil seal lip MUST NOT roll over the edge of the tool.
1. Position the rear crankshaft oil seal adaptor (5) with Assembly Sleeve 8944 on crankshaft so that the
dowel sleeves fit into guide holes. Care must be taken so that oil pan gasket is not damaged.
2. Install the rear crankshaft seal/adaptor to crankcase bolts (8) and tighten to 9.N.m (80 lbs. in).
3. Tighten the M6 oil pan bolts to 9N.m (80 lbs in) and the M8 bolts to 20 N.m (15 lbs ft).
4. Install fly wheel (1) and tighten bolts (2) in two stages. Torque bolts to 45 N.m (33 lbs. ft.) then 90°.
5. Install transmission assembly. Refer to Transmission and Transfer Case/Manual - Installation .
6. Install the oil pan drain plug and tighten to 25 N.m (18 lbs ft).


2 - ENGINE COVER
7. Lower vehicle.
8. Fill crankcase with the correct engine oil, to the proper level. Refer to owner's manual for specifications.
WARNING: Use extreme caution when the engine is operating. Do not put your
hands near the pulleys, belts or fan. Do not wear loose clothes.

ENGINE MOUNTING
DESCRIPTION
DESCRIPTION
The engine mounting system consists of a four-point system utilizing two load-carrying mounts and two torque
struts. The load-carrying mounts are located on each frame rail. The right mount is a hydro-elastic mount and
left mount is a conventional elastomeric isolator. The two torque controlling struts are attached at the front of
the engine, straddling the right side load-carrying mount. The upper strut connects to the suspension strut tower
and the lower to the suspension crossmember.
OPERATION
OPERATION
The four-point engine mounting system minimizes the transmission of structure-borne engine noise to the
passenger compartment. The load-carrying right and left mounts dampen and isolate vertical motion and
vibration. The two struts absorbs torque reaction forces and torsional vibrations.
INSULATOR, ENGINE MOUNT, LEFT
Removal
REMOVAL
Fig. 176: TIPM Brackett Attaching Bolts - Typical



2. Remove air cleaner assembly.
3. Remove bolts attaching the TIPM bracket (2) to left mount and battery tray (3) . See Fig. 176.
4. Support transaxle with a suitable jack.

1 - BOLT (2)
2 - MOUNT
3 - BRACKET
5. Remove mount to transaxle bolts (1).

6. Remove left mount bracket to body frame rail fasteners.
7. Remove mount (2).
Installation
INSTALLATION

1 - BOLT (2)
2 - MOUNT
3 - BRACKET
1. Install engine mount bracket to body frame rail and tighten fasteners to 28 N.m (250 in. lbs.) . See Fig.
178.
2. Position engine/transaxle for installation of mount to transaxle bolts (1). Install and tighten bolts to 68
N.m (50 ft. lbs.).
3. Remove jack from under transaxle.
Fig. 179: TIPM Brackett Attaching Bolts - Typical


4. Install bolts attaching the TIPM bracket to left mount and battery tray (3).
5. Install air cleaner assembly.
INSULATOR, ENGINE MOUNT, RIGHT
Removal
REMOVAL
Fig. 180: Engine Mount-Right

1 - SNUBBER PAD
3 - BOLTS
1. Remove the engine assembly for the required clearance to access the engine mount. See Engine -
Removal.
NOTE: The right engine mount attaching holes are slightly oversize to
compensate for manufacturing tolerances. The mount has been set at the
manufacturing plant for proper powertrain alignment. Therefore, it is
necessary to mark the position of the mount before the attaching bolts are
loosened.
2. Using a permanent ink marker or equivalent, mark the position of engine mount (2) to the body frame
rail.
3. Remove bolts (3) attaching mount to body . See Fig. 180.
4. Remove mount (2).
Installation
INSTALLATION
Fig. 181: Engine Mount-Right

1 - SNUBBER PAD
3 - BOLTS
1. Position mount (2) into the original position on body frame rail.
NOTE: Engine mount must be installed in the original position on body frame rail.
If mount was not marked or frame rail was replaced, perform the following
procedure.
2. Perform the following procedure if the mount position was not previously marked, or the frame rail was
replaced:
a. Insert new mount (2) loosely in frame rail.
b. Align the four holes in the mount with the mating holes in the rail such that the holes are concentric
(frame rail holes centered in the mount holes).
c. Using a permanent ink marker or equivalent, mark the position of engine mount (2) to the body
frame rail while maintaining mounting hole concentricity.
3. Ensure the mount (2) maintains originally marked position and install mount bolts. Tighten bolts to 28
N.m (250 in. lbs.).
4. Install the engine assembly. See Engine - Installation.
STRUT, TORQUE
Removal
UPPER

1 - BOLT
2 - RIGHT FENDER
4 - NUTS
5 - BOLT
7 - BOLT
9 - BOLT
1. Remove bolts attaching upper torque strut (6) to shock tower bracket (3) and engine mount bracket . See
Fig. 182.
2. Remove the upper torque strut (6).
LOWER


2 - FASCIA
3 - SPLASH SHIELD

2. Remove accessory drive belt splash shield (3). See Fig. 183 .

1 - NUT
2 - PENCIL STRUT
3 - NUT
4 - FLAT WASHER
3. Remove pencil strut (2). See Fig. 184 .

4. Remove bolts attaching lower torque strut (5) to crossmember and strut bracket.
5. Remove lower torque strut (5).
Installation
UPPER

1 - BOLT
2 - RIGHT FENDER
4 - NUT
5 - BOLT
7 - BOLT
8 - LOWER TORQUE STRUT BRACKET
9 - BOLT
11 - BOLT
1. Position the upper torque strut (6) into mounting location.

2. Install the torque strut (6) mounting bolts and perform the torque strut adjustment procedure. See
Engine/Engine Mounting/STRUT, Torque - Adjustments.
LOWER

1 - NUT
2 - PENCIL STRUT
3 - NUT
4 - FLAT WASHER
1. Position lower torque strut (5) into mounting locations.

2. Install mounting bolts and perform torque strut adjustment procedure. See Engine/Engine
Mounting/STRUT, Torque - Adjustments.
3. Install pencil strut (2) and tighten nuts (3) to 58 N.m (43 ft. lbs.).


2 - FASCIA
3 - SPLASH SHIELD
4. Install accessory belt splash shield (3) and lower vehicle.
Adjustments
ENGINE TORQUE STRUT ADJUSTMENT
The upper and lower torque struts need to be adjusted together to assure proper engine positioning and engine
mount loading. Whenever a torque strut bolt(s) is loosened, this procedure must be performed.

1 - NUT
2 - PENCIL STRUT
3 - NUT
4 - FLAT WASHER
1. Remove accessory drive belt splash shield.

2. Remove pencil strut (2).
3. Loosen the upper and lower torque strut (5) attaching bolt at the suspension crossmember and shock
tower bracket.
Fig. 189: Floor Jack Positioning

1 - WOOD BLOCK
2 - FLOOR JACK
4. The engine position may now be adjusted by positioning a suitable floor jack on the forward edge of the
transmission bell housing.
NOTE: The floor jack must be positioned as indicated, to prevent minimal upward
lifting of the engine. See Fig. 189.
5. With the engine supported, remove the upper and lower torque strut attachment bolt(s) at shock tower
bracket and suspension crossmember . See Fig. 189. Verify that the torque struts are free to move within
the shock tower bracket and crossmember. Reinstall the torque strut bolt(s), but do not tighten.
Fig. 190: Engine Position Measurement

6. Carefully apply upward force, allowing the upper engine to rotate rearward until the distance between the
center of the rearmost attaching bolt on the engine mount bracket (point "A") and the center of the hole on
the shock tower bracket (point "B") is 119 mm (4.70 in.). See Fig. 190 .
Fig. 191: Torque Strut Bolts

1 - BOLT
2 - RIGHT FENDER
4 - NUT
5 - BOLT
7 - BOLT
8 - LOWER TORQUE STRUT BRACKET
9 - BOLT
11 - BOLT
CAUTION: The engine must be held in position with jack until both the upper
and lower torque strut bolts are tightened.
7. With the engine held at the proper position, tighten both the upper (6) and lower (10) torque strut bolts to
115 N.m (85 ft. lbs.).
8. Remove the floor jack.

1 - NUT
2 - PENCIL STRUT
3 - NUT
4 - FLAT WASHER
9. Install pencil strut (2) and tighten nuts (3) to 58 N.m (43 ft. lbs.).
10. Install accessory drive belt splash shield.
LUBRICATION
JET, PISTON OIL COOLER
Description
DESCRIPTION
Fig. 193: Oil Jet Location

1 - PISTON ASSEMBLY
2 - ENGINE BLOCK
3 - OIL JET
There are four oil jets (3) installed in the engine block (2). See Fig. 193 . These oil jets are used to cool and
lubricate the piston assemblies.
Removal
REMOVAL
Fig. 194: Oil Jet Extraction Claw

1 - SLIDE HAMMER - C-3752

2 - OIL JETS
3 - EXTRACTION CLAW 9746
The engine must be removed from the vehicle and completely disassembled to replace the oil jets (2).
1. Remove engine from vehicle.

2. Completely disassemble engine.
3. Using an Extraction Claw 9746 (3) and Slide Hammer C-3752 (1), remove the oil jets (2) from engine
block.
Installation
INSTALLATION
Fig. 195: Oil Jet Installation

1 - OIL JET INSTALLER 8942

2 - ENGINE BLOCK
3 - OIL JET
1. Install oil jet (3) into Oil Jet Installer 8942 (1).
2. Align oil jet (3) in location in engine block (2).
3. Drive oil jets (3) into block (2) using Oil Jet Installer 8942 (1) until oil jet is fully seated into engine
block. See Fig. 195 .
4. Reassemble engine.
5. Install engine into vehicle.
PAN, OIL
Removal
REMOVAL


3. Remove right front wheel.
6. Remove power steering line to oil pan retaining bolts.
7. Disconnect power steering line from steering gear and reposition out of way.
Fig. 197: Oil Cooler/Filter Assembly
1 - OIL COOLER
3 - OIL PAN
4 - OIL FILTER HOUSING
8. Remove charge air cooler pipe to oil pan retaining bolts.

9. Disconnect charge air cooler pipe from turbocharger and reposition out of way.
10. Remove oil cooler/filter assembly (1,4) retaining bolts and reposition assembly out of way. See Fig. 197 .
Fig. 198: A/C Compressor Mount to Oil Pan Brackets

1 - A/C COMPRESSOR MOUNT

2 - A/C COMPRESSOR BRACKET TO OIL PAN
BRACKETS
3 - OIL PAN
11. Remove A/C compressor mount (1) to oil pan brackets. See Fig. 198 .
12. Remove lower torque strut (4). See Engine/Engine Mounting/STRUT, Torque - Removal.
13. Remove oil pan fasteners and remove oil pan.
Installation
INSTALLATION
Fig. 199: Oil Cooler/FilterAssembly

1 - OIL COOLER
3 - OIL PAN
4 - OIL FILTER HOUSING
1. Clean oil pan and all sealing surfaces.

2. Position new oil pan gasket onto pan.
3. Install oil pan. Torque M6 bolts to 9N.m (80 lbs. in.). Torque M8 bolts to 20N.m (177 lbs. in.). Torque
transmission to oil pan bolts to 40 N.m (30 lbs. ft.).
4. Reposition oil cooler assembly (1) and install retaining bolts. Torque bolts to 20N.m(177 lbs. in.).
Fig. 200: A/C Compressor Mount to Oil Pan Brackets

1 - A/C COMPRESSOR MOUNT

2 - A/C COMPRESSOR BRACKET TO OIL PAN
BRACKETS
3 - OIL PAN
5. Install lower torque strut (4). See Engine/Engine Mounting/STRUT, Torque - Installation.
6. Install A/C compressor mount (1) to oil pan brackets. See Fig. 198 . Torque bolts to 20 N.m(177 lbs. in.).
7. Connect charge air cooler pipe to turbocharger.
8. Install charge air cooler pipe to oil pan retaining bolts.
9. Connect power steering line to steering gear.
10. Install power steering line to oil pan retaining bolts.


11. Install accessory drive belt splash shield (2) and engine compartment lower silencer (1). See Fig. 196 .
12. Install right front wheel.
13. Lower vehicle.
14. Refill engine oil and power steering fluid to proper specifications.
PUMP, ENGINE OIL
Removal
REMOVAL
Fig. 202: Oil Pump Assembly

1 - OIL PUMP CHAIN TENSIONER

2 - OIL PUMP RETAINING BOLTS
3 - OIL PUMP
4 - OIL PUMP PICKUP
5 - OIL PUMP SPROCKET
6 - OIL PUMP RETAINING BOLT
7 - CYLINDER BLOCK
8 - OIL PUMP CHAIN

4. Remove oil pan. See Engine/Lubrication/PAN, Oil - Removal.
5. Remove oil pump retaining bolts (2,6). See Fig. 202 .
6. Push on oil pump chain tensioner (1) to release tension on chain and remove oil pump chain (8) from oil
pump sprocket (5). See Fig. 202 .
7. Remove oil pump (3).
Installation
INSTALLATION
Fig. 203: Oil Pump Assembly

1 - OIL PUMP CHAIN TENSIONER

2 - OIL PUMP RETAINING BOLTS
3 - OIL PUMP
4 - OIL PUMP PICKUP
5 - OIL PUMP SPROCKET
6 - OIL PUMP RETAINING BOLT
7 - CYLINDER BLOCK
8 - OIL PUMP CHAIN
1. Release tension from oil pump chain tensioner (1) and install chain (8) on oil pump sprocket (5).
2. Position oil pump (3) on cylinder block and install retaining bolts (2,6). Torque bolts to 18 N.m(13 lbs.
ft.).
3. Install oil pan. See Engine/Lubrication/PAN, Oil - Installation.
4. Lower vehicle from hoist.
5. Refill engine oil to proper level.
SWITCH, OIL PRESSURE
Description
DESCRIPTION
Fig. 204: Oil Pressure Sensor Location

1 - VIBRATION DAMPER/CRANKSHAFT PULLEY

2 - OIL PRESSURE SWITCH
The oil pressure switch (2) is located on the right front side of the engine block. See Fig. 204 . The oil pressure
switch is a pressure sensitive switch that is activated by the engine's oil pressure (in the main oil gallery). The
switch is a single terminal device.
Operation
OPERATION
Fig. 205: Oil Pressure Sensor Location

1 - VIBRATION DAMPER/CRANKSHAFT PULLEY

2 - OIL PRESSURE SWITCH
The oil pressure switch (2) is normally "Closed." The switch changes from a "Closed" circuit to an "Open"
circuit, on increasing pressure of 7 psig. The oil pressure switch changes from an "Open" circuit to a "Closed"
circuit, on decreasing pressure, between 2 psig and 4 psig.
MANIFOLDS
MANIFOLD, EXHAUST
Removal
REMOVAL


2. Remove engine cover.
Fig. 207: AIR CLEANER HOUSING

3. Disconnect mass air flow sensor connector (1) and inlet pressure sensor connector (2).
Fig. 208: AIR INLET HOSE

4. Remove air inlet hose (1) from air cleaner housing and turbo charger.
5. Disconnect crankcase vent heater connector and remove crankcase vent hose.
6. Remove V-band clamp from turbocharger.
7. Raise vehicle. remove lower silencer shield.
Fig. 209: PARTICULATE FILTER

8. Remove pre-catalytic convertor (2).
Fig. 210: CAT SUPPORT BRACKET

9. Disconnect oxygen sensor connector.

10. Remove cat support bracket (1) and remove cat.
Fig. 211: CHARGE AIR PIPE MOUNT

11. Remove charge air tube mounting bolts (3).
Fig. 212: CHARGE AIR PIPE

12. Remove charge air tube bolts (5) at turbo charger and reposition tube.
13. Remove turbocharger support bracket (3).
14. Remove oil drain back tube.
15. Disconnect boost pressure servo motor connector.
Fig. 213: TURBO OIL FEED

16. Remove turbocharger oil feed tube retaining bolt (1). Remove oil feed tube (2) with turbocharger.
Fig. 214: TURBO

17. Remove turbocharger mounting bolts (1) and remove turbocharger (3).
Fig. 215: EXHAUST MANIFOLD BOLTS

18. Remove exhaust manifold retaining nuts and remove manifold (1).
Cleaning
CLEANING
1. Discard gasket (if equipped) and clean all surfaces of manifold and cylinder head.
Inspection
INSPECTION
1. Inspect manifold gasket surfaces for flatness with straight edge. Surface must be flat within 0.15 mm per
300 mm (0.006 in. per foot) of manifold length.
2. Inspect manifolds for cracks or distortion. Replace manifold as necessary.
Installation
INSTALLATION
Fig. 216: EXHAUST MANIFOLD TORQUE SEQUENCE

1. Install exhaust manifold and toque manifold retaining nuts to 23 N.m (200 in. lbs.) in proper sequence.
See Fig. 216.
Fig. 217: Turbocharger

2. Install turbocharger (3) and torque mounting bolts (1) to 23 N.m (200 in. lbs.).
Fig. 218: Oil Feed Tube O-Ring

3. Inspect oil feed tube O-ring (2 ) and replace if damaged.
Fig. 219: Turbocharger Oil Feed

4. Install turbocharger oil feed tube (2) and tighten retaining bolt (1).

5. Connect boost pressure servo motor connector (1).

6. Install oil drain back tube (4).
7. Install turbocharger support bracket (3).
8. Install charge air tube and tighten retaining bolts at turbocharger (5).
Fig. 221: CHARGE AIR PIPE MOUNT

9. Install charge air tube mounting bolts (3).
Fig. 222: Catalytic Converter Support Bracket

10. Install cat and cat support bracket. Tighten cat support retaining bolts.
11. Connect oxygen sensor connector.
Fig. 223: Pre Catalytic Converter

12. Install particulate filter.
Fig. 224: LOWER SILENCER

13. Install lower silencer shield (1) and lower vehicle.
Fig. 225: AIR INLET HOSE

14. Install and tighten V-band clamp at turbocharger.

15. Install crankcase vent hose (3) and connect crankcase vent heater connector.
16. Install air inlet hose (1) to air cleaner housing and turbocharger.


2 - ENGINE COVER
17. Install engine cover (2).

MANIFOLD, INTAKE
Description
INTAKE MANIFOLD
Fig. 228: INTAKE MANIFOLD

The intake manifold is one-piece design and is made of a composite material. See Fig. 228 .
INTAKE MANIFOLD SWIRL VALVE
The intake manifold swirl valve is located in the bottom of the intake manifold. See Fig. 229 .
Fig. 229: INTAKE MANIFOLD SWIRL VALVE LOCATION

1 - FUEL RAIL
2 - INTAKE MANIFOLD
3 - INTAKE MANIFOLD SWIRL VALVE
SWIRL VALVE ACTUATOR SOLENOID
Fig. 230: SWIRL ACTUATOR SOLENOID

1 - SWIRL ACTUATOR OUTPUT HOSE

2 - WASTEGATE SOLENOID
3 - SWIRL ACTUATOR SOLENOID
The swirl actuator solenoid (1) is mounted next to the coolant recovery pressure container behind the wastegate
solenoid. See Fig. 230 .
Operation
A swirl and a charge inlet port are provided in the intake manifold for each cylinder. See Fig. 231 . The charge
inlet port can be closed by means of flaps. The flaps are connected to each other by means of a linkage, which is
operated by the swirl valve actuator . See Fig. 231. They are held in the open position by means of spring force.
In the lower engine speed and load range all the charge inlet ports are sealed off by the flaps. The entire air
flows through the swirl inlet ports only. This results in high air swirling which in turn produces more effective
mixing of the fuel with the air, which improves combustion and reduces the amount of soot particulants in the
exhaust.
As engine speed and loads rise, the charge inlet ports are continuously opened to obtain the best possible ratio
between air swirling and air mass for each engine operating point, which will optimize exhaust characteristics
and engine power output.
The position of the flaps in the charge inlet ports is determined by the map stored in the Engine Control Module
(ECM). The swirl valve actuator is actuated by the swirl valve actuator solenoid. This is a PWM solenoid.
Fig. 231: INTAKE MANIFOLD SWIRL VALVE COMPONENTS

1 - CHARGE INLET PORT

2 - FLAP
3 - VACUUM PORT FROM SOLENOID
4 - SWIRL VALVE ACTUATOR
SWIRL ACTUATOR SOLENOID
The swirl actuator solenoid is used to control the amount of vacuum supplied to the swirl valve actuator.
Removal
INTAKE MANIFOLD
Fig. 232: Intake Manifold Components

1 - FUEL RAIL
2 - HIGH PRESSURE FUEL LINE BRACKETS
4 - SWIRL VALVE ACTUATOR VACUUM HOSE
5 - INTAKE MANIFOLD

3. Discharge air conditioning system (refer to REFRIGERANT SYSTEM EVACUATE ).
6. Remove radiator closure panel. Refer to Body/Exterior/CROSSMEMBER, Radiator - Removal .
7. Disconnect upper radiator hose from radiator.
9. Disconnect lower radiator hose at radiator.
10. Disconnect cooling fan electrical connector.
11. Lower vehicle.
12. Disconnect both A/C lines at condenser.
13. Remove A/C condenser to radiator mounting screws and remove condenser.
14. Unclip charge air cooler from radiator.
15. Lift radiator and cooling fan assembly from vehicle.
16. Disconnect swirl valve actuator hose at actuator. See Fig. 232 .

17. Disconnect air inlet hose (3) from intake manifold (1).

1 - FUEL RAIL
2 - HIGH PRESSURE FUEL LINE BRACKETS
4 - SWIRL VALVE ACTUATOR VACUUM HOSE
5 - INTAKE MANIFOLD
18. Remove high pressure fuel line to fuel rail retaining brackets (2). See Fig. 232 .

19. Remove remaining intake manifold retaining bolts and remove manifold from engine. See Fig. 233 .
1. Remove intake manifold (2). See Engine/Manifolds/MANIFOLD, Intake - Removal.

2. Remove swirl valve solenoid (3)
Cleaning
CLEANING
1. Discard gasket(s).
2. Clean all sealing surfaces.
Inspection
INSPECTION
1. Inspect manifold for cracks or distortion. Replace manifold if necessary.

2. Inspect manifold for gasket surface damage or warpage. Replace manifold if necessary.
Installation
INTAKE MANIFOLD
Fig. 237: Intake Manifold Seals

1 - INTAKE MANIFOLD
2 - INTAKE MANIFOLD SEALS
1. Clean gaskets/seals mating surfaces.

2. Install new intake manifold seals on intake manifold. See Fig. 237 .

3. Place intake (5) on cylinder head and install retaining bolts. Be sure to install high pressure fuel line
brackets (2) in proper position. Tighten bolts to 20 N.m (14.7 lbs. ft.).
4. Connect air inlet hose at intake manifold.
5. Connect swirl valve actuator hose at actuator.
6. Lower radiator and cooling fan assembly in vehicle. Attach charge air cooler to radiator.
7. Attach A/C condenser to radiator with retaining screws.
8. Connect both A/C lines at condenser.
10. Connect cooling fan electrical connector.
11. Connect lower radiator hose at radiator.
12. Lower vehicle.
13. Connect upper radiator hose at radiator.
14. Install radiator closure panel. Refer to Body/Exterior/CROSSMEMBER, Radiator - Installation .
15. Install front grille assembly. Refer to Body/Exterior/GRILLE - Installation .

16. Refill cooling system. Refer to SYSTEM FILLING - DIESEL ENGINE .
17. Evacuate and recharge air conditioning system (refer to STANDARD PROCEDURE ).
18. Install engine cover.

1. Install swirl valve solenoid (3) to intake manifold (2).

2. Install intake manifold (2). See Engine/Manifolds/MANIFOLD, Intake - Installation.
TURBOCHARGER SYSTEM
DIAGNOSIS AND TESTING
TURBOCHARGER
Check for Diagnostic Trouble Codes (DTCs) stored in PCM memory. If any DTCs are present, refer to the
appropriate Powertrain Diagnostic Information.
TURBOCHARGER DIAGNOSIS
CONDITION POSSIBLE CAUSES
Low boost pressure, lack of power Clogged air filter
Leaks between engine and turbocharger

Exhaust restriction
Restriction in charge air cooler hose(s)
Wastegate stuck open
Wastegate actuator malfunction
Seized turbocharger shaft
Overboost Wastegate stuck shut
Wastegate actuator malfunction
Noisy operation or vibration Leak(s) in charge air cooler hose(s)
Intake or exhaust leaks
Oil starvation
Worn turbocharger bearings
Damaged turbine/compressor fins
Blue smoke from exhaust Oil return line blocked
Engine breather clogged
Turbocharger shaft seals damaged
COOLER AND HOSES, CHARGE AIR
Removal
CHARGE AIR COOLER HOSES
Fig. 240: Charge Air Cooler & Hoses

NOTE: Fascia is removed for clarification.
1. Remove the upper radiator closure panel. Refer to Body/Exterior/CROSSMEMBER, Radiator -
Removal .
2. Remove the upper charge air inlet tube (1) from the charge air cooler (4) and the inlet elbow (2).
3. Remove the lower charge air outlet tube (3).
CHARGE AIR COOLER
Fig. 241: Upper Radiator Closure Panel and Center Brace

1 - UPPER RADIATOR CLOSURE PANEL

2 - CENTER BRACE

2. Remove air cleaner housing. See Engine/Air Intake System/BODY, Air Cleaner - Removal.
4. Disconnect positive battery cable.
5. Remove battery and battery tray. Refer to Electrical/Battery System/BATTERY - Removal .
6. Remove grille. Refer to Body/Exterior/GRILLE - Removal .
7. Remove upper radiator closure panel (1) and center brace (2). Refer to
Body/Exterior/CROSSMEMBER, Radiator - Removal .
Fig. 242: Cooling Module - 2.4L Turbo

1 - RADIATOR FAN FASTENERS

2 - CHARGE AIR COOLER FASTENERS
3 - RADIATOR FAN CONNECTOR
4 - CHARGE AIR COOLER
8. Remove front bumper fascia. Refer to Frame and Bumpers/Bumpers/FASCIA, Front - Removal .
9. Remove front bumper. Refer to Frame and Bumpers/Bumpers/REINFORCEMENT, Bumper -
Removal .
10. Loosen charge air cooler hose clamps. Disconnect charge air cooler hoses.
11. Remove radiator fan. Refer to Cooling/Engine/FAN, Cooling - Removal .
12. Remove charge air cooler fasteners (2).
13. Remove radiator. Refer to Cooling/Engine/RADIATOR, Engine Cooling - Removal .
14. Remove charge air cooler.
Installation
CHARGE AIR COOLER HOSES
HOSE - CHARGE AIR COOLER TO THROTTLE BODY
Fig. 243: Charge Air Cooler Hoses

1 - HOSE - CHARGE AIR COOLER TO THROTTLE BODY

3 - HOSE - TURBOCHARGER TO CHARGE AIR COOLER
1. Position hose (1) to mounting location.

2. Connect hose (1) to throttle body.
3. Connect hose (1) to charge air cooler (2).
4. Tighten hose clamps to 1.7 N.m (15 in. lbs.).
Fig. 244: IAT Sensor - 2.4L Turbo

1 - HOSE - CHARGE AIR COOLER TO THROTTLE

BODY
2 - IAT SENSOR
3 - TIP HOSE
5. Connect Throttle Inlet Pressure (TIP) hose (3) to charge air cooler hose.
6. Connect Inlet Air Temperature (IAT) sensor connector (2).
7. Install battery tray support bracket.
8. Install battery tray and battery. Refer to Electrical/Battery System/BATTERY - Installation .
9. Connect positive battery cable.
11. Install air cleaner housing. See Engine/Air Intake System/BODY, Air Cleaner - Installation.
HOSE - TURBOCHARGER TO CHARGE AIR COOLER
Fig. 245: Charge Air Cooler Hose


2 - HOSE - TURBOCHARGER TO CHARGE AIR COOLER
3 - NUT
1. Position hose (2) to mounting location.

2. Temporarily install nuts (3) securing charge air cooler hose (2) to structural collar.
3. Connect hose (2) to turbocharger.
4. Connect hose (2) to charge air cooler.
5. Tighten hose clamps to 1.7 N.m (15 in. lbs.).
6. Tighten nuts (3) securing charge air cooler hose to structural collar.
7. Lower vehicle.
CHARGE AIR COOLER
Fig. 246: Charge Air Cooler Locating Tab

1 - LOCATING TAB
2 - LOWER RADIATOR SUPPORT CROSSMEMBER
3 - RADIATOR MOUNT BUSHING
1. Position charge air cooler to mounting location.
NOTE: When lowering radiator, make sure lower radiator pins engage properly
through charge air cooler tabs. See Fig. 246 .
2. Install radiator. Refer to Cooling/Engine/RADIATOR, Engine Cooling - Installation .

3. Install fasteners attaching charge air cooler to radiator. Tighten fasteners to 8 N.m (70 in. lbs.).
4. Install radiator fan. Refer to Cooling/Engine/FAN, Cooling - Installation .
5. Connect charge air cooler hoses. Tighten hose clamps to 1.7 N.m (15 in. lbs.).
6. Install front bumper. Refer to Frame and Bumpers/Bumpers/REINFORCEMENT, Bumper -
Installation .
7. Install front bumper fascia. Refer to Frame and Bumpers/Bumpers/FASCIA, Front - Installation .
8. Install upper radiator closure panel and center brace. Refer to Body/Exterior/CROSSMEMBER,
Radiator - Installation .
9. Install grille. Refer to Body/Exterior/GRILLE - Installation .
10. Install battery tray and battery. Refer to Electrical/Battery System/BATTERY - Installation .
11. Connect positive battery cable.
13. Install air cleaner housing. See Engine/Air Intake System/BODY, Air Cleaner - Installation.
14. Fill cooling system. Refer to Cooling - Standard Procedure .
LINES AND HOSES, TURBOCHARGER, OIL AND COOLANT
Removal
TURBOCHARGER LINES
COOLANT SUPPLY LINE
Fig. 247: Turbocharger Lines and Hoses

Fig. 248: Coolant Lines - Banjo Fittings
1 - COOLANT RETURN LINE

2 - BANJO BOLTS - 30 N.m (22 ft. lbs.)
3 - COOLANT SUPPLY LINE

3. Remove banjo bolt (2) from coolant supply line (3) at turbocharger.
Fig. 249: Coolant Supply Line - Engine Block Fitting

1 - BRASS FITTING - 41 N.m (30 ft. lbs.)

2 - FLARED FITTING - 31 N.m (23 ft. lbs.)
4. Disconnect coolant supply line (3) flared fitting (2) from brass fitting (1) at engine block.
5. Remove coolant supply line.
COOLANT RETURN LINE
Fig. 250: Coolant Return Line Bracket

1 - NUT
3 - HOSE CLAMPS

2. Remove air cleaner housing. See Engine/Air Intake System/BODY, Air Cleaner - Removal.
3. Disconnect Inlet Air Temperature (IAT) sensor connector.
4. Disconnect Throttle Inlet Pressure (TIP) hose from charge air cooler hose.
5. Loosen hose clamp at throttle body.
6. Disconnect charge air cooler hose from throttle body. Reposition charge air cooler hose.
7. Remove fastener securing coolant return line bracket to cylinder head cover stud.
8. Remove hose clamp from coolant return line (2) at heater tube. Disconnect hose from heater tube.
9. Remove banjo bolt from coolant return line at turbocharger.
10. Remove coolant return line.
OIL SUPPLY LINE
Fig. 251: Turbocharger Brackets and Heat Shields

1 - UPPER/LOWER HEAT SHIELDS

2 - TURBOCHARGER SUPPORT BRACKET
3 - ELBOW
4 - ELBOW SUPPORT BRACKET

2. Remove elbow support bracket (4).
Fig. 252: Oil Supply Line - Engine Block Fitting

1 - OIL SUPPLY LINE

6 - OIL COOLER COOLANT LINE
3. Disconnect oil supply line flared fitting (2) from brass fitting (3) at engine block.
4. Lower vehicle.
5. Disconnect oil supply line flared fitting (2) from brass fitting (3) at turbocharger.
Fig. 253: Oil Supply Line - Turbocharger Fitting

1 - OIL SUPPLY LINE

6. Remove oil supply line (1).
OIL RETURN LINE

2. Remove the two fasteners securing the oil return line to the turbocharger.
3. Remove hose clamp from oil return line.
4. Remove oil return line from crankcase nipple.
Installation
TURBOCHARGER LINES
COOLANT SUPPLY LINE
Fig. 254: Coolant Supply Line - Engine Block Fitting


1. If the brass fitting (1) was removed from the engine block, apply thread sealer to the threads and install
into the engine block. Tighten the brass fitting (1) to 41 N.m (30 ft. lbs.).
2. Position the coolant supply line tube (3) onto the brass fitting (1) at the engine block.
3. Install the after run pump hoses to the after run pump.
4. Install NEW washers on the banjo fitting of coolant supply line. Hand start the banjo bolt.
5. Tighten the flared fitting (2) to 31 N.m (23 ft. lbs.).
Fig. 255: Coolant Lines - Banjo Fittings


2 - BANJO BOLTS - 30 N.m (22 ft. lbs.)
6. Tighten the banjo fitting bolts (2) to 30 N.m (22 ft. lbs.).
7. Lower the vehicle.
8. Fill the cooling system. Refer to Cooling - Standard Procedure .
COOLANT RETURN LINE
Fig. 256: Banjo Bolt and Washers

1 - BANJO BOLT
2 - WASHERS
1. Position the coolant return line on the turbocharger.

2. Install NEW washers (2) onto the banjo fitting of the coolant return line. Hand start the banjo bolt.
3. Install the hose onto the thermostat housing.
4. Tighten the banjo bolt to 40 N.m (29.5 ft. lbs.).
5. Secure the coolant return line bracket to the turbocharger housing tighten to 12 N.m (9 ft. lbs.).
6. Fill the cooling system. Refer to Cooling - Standard Procedure .
OIL SUPPLY LINE
1. If the engine block brass fitting (3) or turbocharger brass fitting was removed, apply thread sealer to
threads and install. Tighten the brass fittings (3) to 41 N.m (30 ft. lbs.).
2. Position the oil supply line (1) to the mounting location.
Fig. 257: Oil Supply Line - Turbocharger Fitting

1 - OIL SUPPLY LINE

3. Hand start the flared fitting (2) at turbocharger.

4. Raise the vehicle on hoist.
5. Hand start the flared fitting (2) on the line to the engine block brass fitting (3).
Fig. 258: Oil Supply Line - Engine Block Fitting

1 - OIL SUPPLY LINE

6 - OIL COOLER COOLANT LINE
6. Tighten the flared fittings to 31 N.m (23 ft. lbs.).

OIL RETURN LINE
NOTE: If drain back nipple is not damaged or showing signs of leakage, steps 2, 3, 4,
and 9 can be skipped.
1. Clean gasket surfaces.

2. Using a paint pen, mark the new drain back nipple to a depth of 17 mm (0.669in.) from the end to be
installed in block.
3. Apply MOPAR® Stud'n Bearing mount and adhesive to the drain back nipple.
4. Using Bearing Installer 9723, install the drainback nipple.
5. Install the oil return line hose over the drain back nipple.
6. Install a new gasket.
7. Install the two fasteners securing the oil return tube to the turbocharger. Tighten the fasteners to 12 N.m
(105 in. lbs.).
8. Perform oil change. Refer to Engine/Lubrication/OIL - Standard Procedure .
SOLENOID, WASTEGATE
Description
SOLENOIDS AND VACUUM HARNESS
Fig. 259: Vacuum Harness Schematic

Turbocharged vehicles are equipped with three solenoids that are PCM controlled. They are mounted to the
right shock tower. A vacuum harness connects the solenoids to their respective component.
l Wastegate Actuator Solenoid

l Surge Valve Actuator Solenoid
l Throttle Inlet Pressure (TIP) Solenoid
Removal
WASTEGATE SOLENOID
Fig. 260: Wastegate Solenoid & Electrical Connectors

1. Disconnect the electrical connectors (3, 4 and 5).

2. Remove the nuts (1) the securing the solenoid mounting bracket to the shock tower.
Fig. 261: Nuts Securing Solenoid Mounting Bracket

3. Disconnect vacuum harness connector from solenoid.

4. Push on the solenoid lock tab and slide solenoid off the bracket.
Fig. 262: Solenoid Mounting Bracket

5. If necessary, remove the solenoid mounting bracket.
Installation
WASTEGATE SOLENOID
Fig. 263: Solenoid Mounting Bracket

1. If removed, install the solenoid mounting bracket.

2. Slide the solenoids onto the mounting tab until the lock tab (1) engages.
3. Connect vacuum harness connector to solenoid.
Fig. 264: Nuts Securing Solenoid Mounting Bracket

4. Install the nuts securing the solenoid mounting bracket to the shock tower (1).
Fig. 265: Wastegate Solenoid & Electrical Connectors

5. Connect solenoid electrical connectors (3, 4 and 5).
TURBOCHARGER
Description
TURBOCHARGER
Fig. 266: Turbocharger - Typical

1 - TURBINE SECTION
2 - EXHAUST GAS
3 - BEARING HOUSING
4 - COMPRESSOR SECTION
5 - INLET AIR
6 - COMPRESSED AIR TO ENGINE
7 - EXHAUST GAS
8 - EXHAUST GAS TO EXHAUST PIPE
CAUTION: The turbocharger is a performance part and must not be tampered with.
Tampering with the wastegate components can reduce durability by
increasing cylinder pressure and thermal loading due to incorrect inlet and
exhaust manifold pressure. Poor fuel economy and failure to meet
regulatory emissions laws may result. Increasing the turbocharger boost
WILL NOT increase engine power.
The turbocharger is an exhaust-driven supercharger which increases the pressure and density of the air entering
the engine. With the increase of air entering the engine, more fuel can be injected into the cylinders, which
creates more power during combustion.
The turbocharger assembly consists of four (4) major component systems:
l Turbine section (1)

l Compressor section (4)
l Bearing housing (3)
l Wastegate
Operation
OPERATION
Fig. 267: Wastegate Operation

1 - SIGNAL LINE
2 - EXHAUST BYPASS VALVE
3 - WASTEGATE
4 - EXHAUST
5 - TURBINE
6 - EXHAUST BYPASS VALVE
7 - WASTEGATE
8 - EXHAUST
9 - TURBINE
10 - SIGNAL LINE
Exhaust gas pressure and energy drive the turbine, which in turn drives a centrifugal compressor that
compresses the inlet air, and forces the air into the engine through the charge air cooler and plumbing. Since
heat is a by-product of this compression, the air must pass through a charge air cooler to cool the incoming air
and maintain power and efficiency.
Increasing air flow to the engine provides:
l Improved engine performance

l Improved operating economy
l Altitude compensation
The turbocharger also uses a wastegate (3), which regulates intake manifold air pressure and prevents over
boosting at high engine speeds. When the wastegate valve is closed, all of the exhaust gases flow through the
turbine wheel. As the intake manifold pressure increases, the wastegate actuator opens the valve, diverting some
of the exhaust gases away from the turbine wheel. This limits turbine shaft speed and air output from the
impeller.
Fig. 268: Turbocharger Oil Supply and Drain

1 - BEARINGS
2 - OIL SUPPLY (FROM ENGINE BLOCK)
3 - OIL RETURN (TO OIL PAN)
The turbocharger is cooled by engine coolant. The coolant is delivered to the turbocharger by a supply line that
connects from engine block to the turbocharger. A coolant return line connects the turbocharger to heater tubes.
The turbocharger is lubricated by engine oil that is pressurized, cooled, and filtered. The oil is delivered to the
turbocharger by a supply line that is tapped into the cylinder block. The oil travels into the bearing housing,
where it lubricates the shaft and bearings (1). A return pipe at the bottom of the bearing housing, routes the
engine oil back to the crankcase.
The most common turbocharger failure is bearing failure related to repeated hot shutdowns with inadequate
"cool-down" periods. A sudden engine shut down after prolonged operation will result in the transfer of heat
from the turbine section of the turbocharger to the bearing housing. This causes the oil to overheat and break
down, which causes bearing and shaft damage the next time the vehicle is started.
Letting the engine idle after extended operation allows the turbine housing to cool to normal operating
temperature. The following chart should be used as a guide in determining the amount of engine idle time
required to sufficiently cool down the turbocharger before shut down, depending upon the type of driving and
the amount of cargo.
TURBOCHARGER "COOL DOWN" CHART

Driving Idle Time (in minutes)
Conditions Before Shut Down
Normal Driving Not required
Aggressive Driving or Heavily Loaded 3
Trailer Tow 5
Removal
DIESEL ENGINE

1 - BATTERY
2 - PASSENGER SEAT
1. Disconnect negative battery (1) cable located under passenger seat (2).



4. Remove engine compartment lower silencer (1).
5. Disconnect turbocharger outlet pipe to charge air cooler at turbocharger (2).

6. Disconnect exhaust pipe from turbocharger downpipe.
7. Remove turbocharger downpipe to turbo retaining bolts and remove downpipe.

8. Disconnect turbocharger oil return line at turbocharger.

9. Lower vehicle.
10. Remove coolant recovery pressure container. Refer to Cooling/Engine/BOTTLE, Coolant Recovery -
Removal .
11. Disconnect air cleaner to turbocharger hose at turbocharger.
12. Remove exhaust manifold heat shield.
13. Disconnect turbocharger oil feed line at turbocharger and cylinder head. Remove exhaust manifold
retaining nut holding oil feed line and remove line from engine.

14. Disconnect wastegate actuator hose at actuator.

15. Remove exhaust manifold retaining nuts and remove exhaust manifold (2) and turbocharger assembly
from cylinder head.
16. Clamp exhaust manifold/turbocharger assembly into a vise. Separate turbocharger from exhaust manifold.
Inspection
INSPECTION
Fig. 274: Inspect Compressor Housing for Impeller Rubbing Condition

Visually inspect the turbocharger and exhaust manifold gasket surfaces. Replace stripped or eroded mounting
studs.
1. Visually inspect the turbocharger for cracks. The following cracks are NOT acceptable:
l Cracks in the turbine and compressor housing that go completely through.
l Cracks in the mounting flange that are longer than 15 mm (0.6 in.).
l Cracks in the mounting flange that intersect bolt through-holes.
l Two (2) Cracks in the mounting flange that are closer than 6.4 mm (0.25 in.) together.
2. Visually inspect the impeller and compressor wheel fins for nicks, cracks, or chips.
3. Visually inspect the turbocharger compressor housing for an impeller rubbing condition. Replace the
turbocharger if the condition exists.
Installation
DIESEL ENGINE

1. Attach turbocharger assembly (2) to exhaust manifold. Torque bolts to 30 N.m (22 lbs. ft.).
2. Reposition exhaust manifold/turbocharger assembly (2) on cylinder head.
3. Install turbocharger oil feed line. Torque line at turbocharger to 30 N.m (22 lbs. ft.). Torque retaining
bolts at cylinder head to 22 N.m(16 lbs. ft.).
4. Torque exhaust manifold nuts to 30 N.m (22 lbs. ft.).

5. Install exhaust manifold heat shield.

6. Install turbocharger inlet hose from air cleaner at turbocharger.
7. Connect wastegate actuator hose at actuator.
8. Install coolant recovery pressure container. Refer to Cooling/Engine/BOTTLE, Coolant Recovery -
Installation .
9. Raise vehicle on hoist
10. Install oil return line at turbocharger. Torque bolts to 9 N.m (80 lbs. in.).
11. Install turbo downpipe to turbocharger. Torque bolts to 30 N.m (22 lbs. ft.).

12. Connect exhaust pipe to turbocharger downpipe. Torque fasteners to 28 N.m (250 in. lbs.).
13. Connect turbocharger outlet pipe to charge air cooler at turbocharger.


14. Install engine compartment lower silencer (1).

15. Lower vehicle.
16. Refill cooling system. Refer to SYSTEM FILLING - DIESEL ENGINE .

1 - BATTERY
2 - PASSENGER SEAT
18. Connect negative battery cable located under passenger seat (2).
VALVE TIMING
CHAIN, TIMING
Removal
BOTTOM GUIDE RAIL
Fig. 280: Bottom Guide Rail

1 - TIMING CHAIN COVER

2 - BOTTOM SLIDE RAIL
3 - BEARING PIN
4 - OIL PAN
The engine must be removed to service the bottom guide rail.

5. Support engine on suitable engine stand.
7. Remove cylinder head front cover. See Engine/Cylinder Head - Removal.
NOTE: Oil pan DOES NOT need to be removed. Remove bolts in the area of timing
case cover then loosen the remaining bolts.
NOTE: Remove timing case cover carefully. Care must be taken not to damage oil
pan gasket.
8. Remove timing chain cover (1). See Engine/Valve Timing/COVER(S), Engine Timing - Removal.
9. Remove guide rail (2) from bearing pin (3). See Fig. 281 .
INTERMEDIATE GEAR


2 - INTAKE CAM SPROCKET
1. Disconnect negative battery cable located under the passenger seat.

4. Remove the intermediate gear cover (3). See Fig. 281 .


rotate the engine using the camshaft sprocket bolt.
aligned.
1 - ENGINE BLOCK
2 - CRANKSHAFT LOCK 8933
6. Install crankshaft lock 8933 (2). See Fig. 284 .


7. Install Camshaft Locking Pin 8929 (1) through first camshaft bearing cap into hole in the inlet camshaft
sprocket to lock inlet camshaft. See Fig. 285 .
8. Remove timing chain tensioner. See Engine/Valve Timing/CHAIN, Timing - Removal.
9. Remove cylinder head front cover. See Engine/Cylinder Head - Removal.
10. Remove top slide rail. See Engine/Cylinder Head - Removal.


2 - INTAKE CAMSHAFT
3 - DOWEL PIN
11. Mark camshaft sprocket relative to timing chain.

12. Unbolt camshaft sprocket (1) from exhaust camshaft.
NOTE: Note position of dowel pin for camshaft sprocket alignment during
reassembly.
13. Secure camshaft sprocket to timing chain with tie strap.
14. Remove camshaft sprocket.

15. Remove intermediate gear (5) and bushing (4). See Fig. 286. .
TIMING CHAIN TENSIONING RAIL
Fig. 286: Timing Chain Tensioning Rail


2 - TENSIONING RAIL
3 - BEARING PIN
4 - OIL PAN

2. Remove cylinder head cover.
NOTE: Oil pan DOES NOT need to be removed. Remove bolts in the area of timing
case cover then loosen the remaining bolts.
NOTE: Remove timing case cover carefully. Care must be taken not to damage oil
pan gasket.
4. Remove timing chain tensioner.

5. Remove timing chain cover (1). See Engine/Valve Timing/COVER(S), Engine Timing - Removal.
6. Remove tensioning rail (2) from bearing pin (3).
TIMING CHAIN
Fig. 287: Timing Chain Retainer 8931

1 - TIMING CHAIN RETAINER 8931

4. Remove cylinder head front cover and guide rail. See Engine/Valve Timing/CHAIN, Timing -
Removal.
5. Remove timing chain tensioner. See Engine/Valve Timing/TENSIONER, Engine Timing - Removal.
CAUTION: Cover timing chain cover recess to prevent foreign material from
entering engine.
6. Attach timing chain retainer 8931 (1) to cylinder head with bolts supplied. See Fig. 288 .
Fig. 288: PIN POSITION

NOTE: When fitting the thrust spindle, ensure that the thrust pin is positioned at
the left timing chain pin of a chain link. See Fig. 288 .
7. Assemble special tool #9312-1 (1) using 9312-3 (5) and 9312-4 (4). Install insert #9312-13 (3) and retain
with screw provided. See Fig. 289 .
Fig. 289: CHAIN BREAKER

1 - SPECIAL TOOL #9312-1

CAUTION: Care must be taken not to drop timing chain plates into the engine
once the timing chain is separated.
NOTE: when installing special tool #9312-1 onto timing chain link, be sure to back
off the smaller nut of the thrust pin #9312-3 until the pin is recessed inside
of spindle 9312-4. Screw the thrust spindle #9312-4 in until it is seated and
aligned properly over the left timing chain pin of a chain link, as viewed
from behind the engine. See Fig. 289 .
8. Screw the thrust pin in and separate the timing chain. See Fig. 289 .
9. Unscrew the thrust spindle and remove the tool.
10. Remove pressed - out timing chain pin from chain separation tool.
Fig. 290: Timing Chain Temporary Link - Typical


2 - TIMING CHAIN ASSEMBLY LINK
3 - ALIGNMENT PINS
4 - TOP GUIDE RAIL

11. Connect new timing chain and old timing chain with assembly link, assembly plate and locking element,
and secure. See Fig. 289 .
CAUTION: IT IS ESSENTIAL that the installation procedure for the timing chain
is followed exactly. Failure to do so will result in severe engine
damage.
Installation
BOTTOM GUIDE RAIL
NOTE: Carefully clean all mating surfaces with appropriate solvents to assure that no
grease or oil is present during reassembly.
Fig. 291: Bottom Guide Rail


2 - BOTTOM SLIDE RAIL
3 - BEARING PIN
4 - OIL PAN
1. Install bottom slide rail (2) on bearing pin (3).

2. Install timing chain cover (1). See Engine/Valve Timing/COVER(S), Engine Timing - Installation.
3. Install cylinder head front cover. See Engine/Cylinder Head - Installation.
4. Install cylinder head cover. See Engine/Cylinder Head/COVER(S), Cylinder Head - Installation.
5. Install engine. See Engine - Installation.

NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.

INTERMEDIATE GEAR
NOTE: Refer to appropriate injector servicing procedures for cleaning of injectors and
recesses.


2 - INTAKE CAMSHAFT
3 - DOWEL PIN
1. Install intermediate gear (5) and bushing (4). Tighten bolt to 40N.m (30 lbs. ft.)
2. Install camshaft sprocket (1), noting dowel pin alignment. Tighten bolt to 18 N.m (159 lbs. in.).
3. Remove tie strap retaining timing chain to sprocket.


4. Install top slide rail. See Engine/Valve Timing/CHAIN, Timing - Installation.

5. Install intermediate gear cover (3).
6. Install cylinder head front cover. See Engine/Cylinder Head - Installation.
7. Install timing chain tensioner with new gasket. See Engine/Valve Timing/CHAIN, Timing -
Installation.
NOTE: Inspect basic position of camshaft and reset if necessary.

1 - ENGINE BLOCK
8. Remove crankshaft lock 8933 (2).


9. Remove camshaft locking pin 8929 (1).


NOT WEAR LOOSE CLOTHING.

TIMING CHAIN TENSIONING RAIL
Fig. 296: Timing Chain Tensioning Rail


2 - TENSIONING RAIL
3 - BEARING PIN
4 - OIL PAN
1. Install tensioning rail (2) on bearing pin (3).

2. Install timing chain tensioner with new seal.
3. Install timing chain cover. See Engine/Valve Timing/COVER(S), Engine Timing - Installation.
4. Install cylinder head cover.

NOT WEAR LOOSE CLOTHES.

Adjustments
TIMING CHAIN
CAUTION: IT IS ESSENTIAL that the installation procedure is followed exactly. Failure

to do so will result in severe engine damage.
CAUTION: Cover timing case recesses to prevent foreign material from entering
engine.
Fig. 297: Timing Chain Temporary Chain Link - Typical


2 - TIMING CHAIN ASSEMBLY LINK
3 - ALIGNMENT PINS
4 - TOP GUIDE RAIL
1. Connect new timing chain and old timing chain with the assembly link (2), the assembly plate and the
assembly locking element, and secure. See Fig. 289 .
NOTE: Always keep new timing chain meshed with camshaft sprocket.
NOTE: Rotate engine at crankshaft only. DO NOT crank engine and DO NOT rotate
engine backward. See Fig. 289 .
NOTE: Draw out the end of old timing chain evenly as it becomes free, to the
same extent that new timing chain is drawn in. See Fig. 289 .
2. Draw in new timing chain by rotating the crankshaft slowly in direction of rotation of engine until the
ends of the new timing chain meet and can be connected. See Fig. 289 .
Fig. 298: NEW AND OLD CHAIN

1 - OLD CHAIN
2 - NEW CHAIN
3 - SPECIAL TOOL 8931
4 - TEMPORARY LINK
NOTE: Assembly link is only an assembly aid and NOT designed for engine
running.
3. Remove assembly link locking element (4), outer plate and link. See Fig. 299 .
4. Engage both halves of the new timing chain into the timing chain gear.
Fig. 299: LINK PLATE HOLDER

1 - GUIDE LINK
2 - NEW CENTER LINK PLATE
3 - NEW LINK
NOTE: The guide link will hold the new center link plate in place while the link is
pressed in place.
5. Install the new chain center link plate. Insert the guide link into the new center plate. See Fig. 300 .
Fig. 300: LINK INSTALLER
1 - SPECIAL TOOL 9312-1

3 - NEW LINK
4 - SPECIAL TOOL 8931
5 - SPECIAL TOOL 9312A-7
6. Assemble special tools 9312-1, 9312A-7, 9312-10 and install on new timing chain. See Fig. 301 .
CAUTION: Cover voids in timing chain cover. Be careful not to allow the guide
link to fall into the timing chain cover as the new link is pressed in.
7. Tighten spindle until link plate is fully seated against the timing chain. Remove special tool assembly.
Fig. 301: LINK PLATE INSTALLER


2 - SPECIAL TOOL 9312-8A
3 - NEW LINK PLATE
8. Assemble special tool 9312-1 with 9312-8A, and 9312-6. See Fig. 302 .
NOTE: The outer plate is held magnetically by link plate installation tool.
9. Install new link plate into 9312-8A. See Fig. 302 .
Fig. 302: INSTALLING LINK PLATE


3 - NEW LINK PLATE
NOTE: When turning spindle of the link plate installation tool, be sure that pins of
riveted link are inserted into holes of outer plate. See Fig. 303 .
10. Install special tool assembly onto the timing chain and tighten spindle until link plate is fully seated and
remove tool. See Fig. 303 .
Fig. 303: PEEN TOOL


11. Assemble special tool 9312-1 with 9312-11A, and 9312-6 and position onto the timing chain. See Fig.
304 .
NOTE: Ensure that the riveted link and riveting tool are aligned.
12. Position riveting tool exactly over middle of pin.

13. Tighten spindle to firmly seat 9312-11A against chain. See Fig. 304 . Repeat process for both link rivets.
Fig. 304: Rivet Inspection

14. Remove special tool and inspect rivets to ensure they have been properly peened. See Fig. 304 . Repeat
process if necessary.
15. Install cylinder head front cover and guide rail. See Engine/Cylinder Head - Installation.
16. Install timing chain tensioner. See Engine/Valve Timing/CHAIN, Timing - Installation.
WARNING: Use extreme caution when the engine is operating. Do not put your
hands near the pulleys belts or fan. Do not wear loose clothes.
COVER(S), ENGINE TIMING
Removal
REMOVAL
The engine must be removed from the vehicle to remove the timing chain cover.
WARNING: Do not open cooling system unless temperature is below 90°C (194°F).
Open cap slowly to release pressure. Store coolant in approved container
only. Risk of injury to skin and eyes from scalding coolant. Wear
protective gloves, clothing and eye wear.


5. Support engine on suitable engine stand.


crank the engine at the bolt of the camshaft sprocket.
aligned.

8. Install crankshaft lock 8933 (2).

11. Remove vibration damper/crankshaft pulley. Refer to Engine/Engine Block/DAMPER, Vibration -
Removal .
NOTE: Remove the bolts in area of timing chain cover. Loosen all other oil pan
bolts.
Fig. 310: Timing Chain Cover

13. Remove oil pan bolts.

14. Remove M8 bolts of cylinder head on timing chain cover.
15. Remove timing chain cover retaining bolts and remove cover (2) from engine. See Fig. 310 .
16. Remove remaining ancillary components attached to the timing chain cover.
Installation
INSTALLATION
NOTE: Thoroughly clean all mating surfaces with the appropriate solvents to assure
that no grease or oil is present during assembly.
Fig. 311: Timing Chain Cover Sealing Surface

1. Inspect cylinder head gasket and oil pan gasket. If damaged, replace.
2. Replace front crankshaft seal. Refer to Engine/Engine Block/SEAL, Crankshaft Oil - Installation .
3. Install ancillary components to timing case cover.
4. Apply sealant to the marked surfaces (2) with a bead thickness of 1.5 ± 0.5 mm. See Fig. 312 .
NOTE: Install timing cover within 10 minutes after applying sealant. Do not spread
sealant bead.
NOTE: Do not seal pressurized oil galleries to the crankcase. Sealant applied at
these points is entrained by the oil flow and blocks the oil supply
passages.
Fig. 312: Timing Chain Cover

5. Position and install timing chain cover (2). Tighten bolts to 20 N.m (177 lbs in).
6. Install M8 bolts of cylinder head on timing case cover. Tighten bolts to 20 N.m (177 lbs in).
7. Position and install the oil pan. Tighten M6 bolts to 9 N.m (80 lbs in) and M8 bolts to 20 N.m (177 lbs
in).
8. Install vibration damper/crankshaft pulley. Tighten M8.8 bolt in two stages, 200N.m (147 lbs ft.) then
90°, M10.9 bolt 325N.m (240 lbs ft) then 90°.

9. Install cylinder head front cover (5). See Engine/Cylinder Head - Installation.
Installation.

12. Remove crankshaft lock 8933 (2).

13. Install engine. See Engine - Installation.

14. Fill coolant to the proper level, with the proper coolant.
15. Tighten oil drain plug to 30 N.m (265 lbs in).
16. Fill crankcase with the correct oil, to the proper level. Refer to owner's manual for specifications.
WARNING: Refer to Fuel System/Fuel Injection - Standard Procedure .


2 - ENGINE COVER

TENSIONER, ENGINE TIMING
Removal
TIMING CHAIN TENSIONER
Fig. 317: ENGINE COMPARTMENT LOWER SILENCER




CAUTION: Rotate engine at crankshaft only. DO NOT rotate the engine with the
bolt of the camshaft sprocket. DO NOT rotate the engine counter
clockwise.
4. Position piston of number #1 cylinder to ignition TDC.

5. Remove timing chain tensioner (1). See Fig. 318 .
Installation
TIMING CHAIN TENSIONER


1. Install timing chain tensioner (1) with new seal (2). Tighten to 80N.m (59 lbs. ft.).
Fig. 320: ENGINE COMPARTMENT LOWER SILENCER


2. Install engine compartment lower silencer (1) and accessory drive belt splash shield (2).
3. Lower vehicle.

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2009 Chrysler PT Cruiser

2009 ENGINE 2.2L Diesel - Service Information - PT Cruiser

2.2L Diesel - Service Information - PT Cruiser

Fig. 1: 2.2L Diesel Engine

miércoles, 10 de marzo de 2021 09:01:49

Eff. Displacement 2148 cm3

Fig. 2: PROPER TOOL USAGE FOR SURFACE PREPARATION

Never use the following to clean gasket surfaces:

l Metal scraper (1).

Fig. 3: PROPER TOOL USAGE FOR SURFACE PREPARATION

Only use the following for cleaning gasket surfaces:

l Solvent or a commercially available gasket remover

COMPRESSION TESTING ENGINE

Fig. 4: #9543 ADAPTER

1. Warm up engine to operating temperature (approximately 80°C, 176°F).

2. Shut off engine.

2.2L COMPRESSION SPECIFICATION

10. Remove Adapter 9543 from cylinder head.

CYLINDER LEAK DOWN TEST

1. Warm engine to operating temperature.

2. Open cooling system cap at coolant recover pressure container.

NOTE: Crank engine at crankshaft in direction of rotation of the engine

6. Position cylinder to be tested to ignition Top Dead Center (DTC).

7. Connect cylinder leak down tester and follow INSPECTING Instruction.

NOTE: If crankshaft rotates, install retaining lock for crankshaft/ring gear.

2. Carry out test of other cylinders in the firing order of engine.

DETERMINING PRESSURE LOSS

The possible causes of pressure loss are:

CHECKING OIL PRESSURE

1. Remove engine cover. See Engine - Removal.

WARNING: Use extreme caution when engine is operating. Do not stand in a

7. Start engine and bring to operating temperature 90°C (194°F).

Fig. 5: Engine Cover Mounts

1. Remove engine cover retaining nuts (1). See Fig. 5 .

Fig. 6: Battery Location

Fig. 7: Engine Cover Mounts

1 - ENGINE COVER RETAINING NUTS

4. Remove engine cover (1). See Engine - Removal.

Fig. 8: Air Cleaner Housing Assembly

1 - TURBOCHARGER INLET HOSE

Fig. 9: TIPM Bracket Attaching Bolts - Typical

1 - Totally Integrated Power Module (TIPM)

10. Remove power distribution center bracket.

Fig. 10: Disconnecting Clutch Hydraulic Line

1 - QUICK CONNECT FITTING

12. Disconnect clutch hydraulic line at transaxle.

Fig. 11: FUEL FILTER

18. Disconnect harness connector (5) at fuel filter/fuel heater.

Fig. 12: Engine Mounting - Right Side

28. Remove two fasteners from upper torque strut (6).

Fig. 13: Splash Shield

1 - RIGHT MOUNT BOLT ACCESS PLUG

38. Remove inner splash shield (3).

Fig. 14: Pencil Strut

Fig. 15: Positioning Engine Cradle Support Post

1 - POST LOCATING HOLES IN BLOCK

3 - POST LOCATING HOLE IN STRUT

Fig. 16: Engine Mounting - Right Side

53. Remove right mount (10) through bolt.