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Section 29 (3.0L Turbo Diesel (Service Information)): Installation

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GC0157455Courtesy of CHRYSLER GROUP, LLC
  1. Carefully align the engine assembly onto the cradle and lower the engine.
  2. Install the right engine mount retaining nut (1) and tighten to 61 N.m (45 ft. lbs.).
    GC0157459Courtesy of CHRYSLER GROUP, LLC
  3. Install the right side engine mount heat shield. Tighten the bolts to 10 N.m (89 in. lbs.).
  4. Support the left side of the engine with a floor jack.
  5. Install the transmission to the engine.
    NOTE:

    Be careful not to damage to transmission pan.

  6. Support the transmission with a suitable jack.
  7. Install the upper five transmission-to-engine bolts and tighten to 55 N.m (41 ft. lbs.).
  8. Install the four transmission-to-oil pan bolts and tighten to 55 N.m (41 ft. lbs.).
  9. Disconnect the chains and remove engine hoist.
    GC0146800Courtesy of CHRYSLER GROUP, LLC
  10. Remove the bolts (2) and the (special tool #VM.10360A-1, Bracket, Engine Lifting (Left Rear)) (1).
    GC0157996Courtesy of CHRYSLER GROUP, LLC
  11. Remove the bolt (2) and the (special tool #VM.10360A-3, Bracket, Engine Lifting (Left Front)) (1).
    GC0146798Courtesy of CHRYSLER GROUP, LLC
  12. Remove the bolts (2) and the (special tool #VM.10360A-2, Bracket, Engine Lifting (Right)) (1).
  13. Install the transfer case and tighten the bolts to 45 N.m (33 ft. lbs.).
  14. Install the transmission cooler lines and be sure the lines are fully seated.
    GC0158317Courtesy of CHRYSLER GROUP, LLC
  15. Snap the Jiffy Tite lock (1) over the line fitting.
  16. Install the bolts securing the transmission cooler lines to oil pan and securely tighten bolts.
  17. Connect the transmission vent hose.
  18. Position and clip the remaining wiring harness to the transmission.
  19. Connect the 13 pin plug connector and turn the connector clockwise to engage.
    GC0174043Courtesy of CHRYSLER GROUP, LLC
  20. Install the Diesel Particulate Filter (DPF) and tighten the V-band clamp nut (1) to 10 N.m (89 in. lbs.).
    GC0174060Courtesy of CHRYSLER GROUP, LLC
  21. Install the rear steady rest bracket nut (1) and tighten to 24 N.m (18 ft. lbs.).
    GC0166212Courtesy of CHRYSLER GROUP, LLC
  22. Install the front steady bracket (2). Tighten the bolts (1) to 55 N.m (41 ft. lbs.).
    GC0166213Courtesy of CHRYSLER GROUP, LLC
  23. Install the front steady bracket nut (1) and tighten to 32 N.m (24 ft. lbs.).
    GC0158083Courtesy of CHRYSLER GROUP, LLC
  24. Install the Differential Pressure Sensor (DPS) and bracket (5) and tighten the bolt (3) to 18 N.m (13 ft. lbs.).
  25. Connect the DPS sensor wire harness connector (2).
  26. Connect the Catalyst Exhaust Gas Temperature (CEGT) sensor wire harness connector (6) and attach to the bracket (5).
  27. Connect the Exhaust Gas Temperature (EGT) sensor 1/2 wire harness connector (4) and attach to the bracket (5).
  28. Verify that the torque converter is pulled flush to the flexplate.
  29. Install the torque converter bolts and tighten to 42 N.m (31 ft. lbs.).
    GC0146865Courtesy of CHRYSLER GROUP, LLC
  30. Install the vibration damper cover (1) and tighten the bolts (2) to 10 N.m (89 in. lbs.).
  31. Install the starter. Refer to STARTER, INSTALLATION .
  32. Remove the floor jack supporting the engine.
  33. Lower the vehicle onto the engine cradle.
  34. Install the front engine cradle bolts and tighten to 175 N.m (129 ft. lbs.).
  35. Install the transmission crossmember. Refer to CROSSMEMBER, TRANSMISSION, INSTALLATION .
  36. Install the rear engine cradle crossmember stiffener brackets and tighten the bolts:
    • Rear engine cradle bolts to 175 N.m (129 ft. lbs.).
    • Six cradle stiffener bracket bolts to 20 N.m (15 ft. lbs.).
  37. Remove the jack stands from the front of the front suspension crossmember, the transmission, and transfer case.
  38. Connect the transfer case wire harness connector and attach wire harness retainers.
    GC0158322Courtesy of CHRYSLER GROUP, LLC
  39. Install the MPR cable (2) into the bracket (3) and lock into place.
    GC0158366Courtesy of CHRYSLER GROUP, LLC
  40. Remove the zip tie (3) from the MPR lever.
  41. Connect the MPR cable (1) to the MPR lever (2).
  42. Install the rear propeller shaft. Refer to INSTALLATION .
  43. Connect the EGT sensor 1/1 wire harness connector.
  44. Using a NEW  gasket, install the Selective Catalytic Reduction (SCR) catalyst to the DPF and tighten the nuts to 32 N.m (24 ft. lbs.).
    GC0157447Courtesy of CHRYSLER GROUP, LLC
  45. Connect the NOx sensor wire harness connector (1).
    GC0172156Courtesy of CHRYSLER GROUP, LLC
  46. Install the NOx module mounting bracket (1) and tighten the nuts (2) to 20 N.m (15 ft. lbs.).
    GC0172151Courtesy of CHRYSLER GROUP, LLC
  47. Attach the NOx wire retainer (1) to the bracket.
    GC0157443Courtesy of CHRYSLER GROUP, LLC
  48. Install the NOx sensor module cover (1) and tighten the fasteners (2) to 20 N.m (15 ft. lbs.).
    GC0172129Courtesy of CHRYSLER GROUP, LLC
  49. Attach the oxygen sensor wire harness connector (3) and wire harness retainers (4) to the bracket (1).
  50. Connect the upstream oxygen sensor wire harness connector (2).
  51. Install the rear propeller shaft heat shield and securely tighten the fasteners.
  52. Install the lower air suspension compressor support and tighten the nuts to 24 N.m (18 ft. lbs.).
    GC0173569Courtesy of CHRYSLER GROUP, LLC
  53. Connect the lower stabilizer link and install a NEW  nut and tighten to 122 N.m (90 ft. lbs.).
    GC0173647Courtesy of CHRYSLER GROUP, LLC
  54. Install the lower clevis bolt/nut (6) and tighten to 235 N.m (173 ft. lbs.).
    GC0117739Courtesy of CHRYSLER GROUP, LLC
  55. Support the outside of the lower control arm with a suitable holding fixture, and raise to position the upper ball joint (2) into the knuckle (3).
  56. With the holding fixture holding the suspension at normal ride height, install the upper ball joint nut (4) and tighten to 95 N.m (70 ft. lbs.).
  57. Connect the left and right wheel speed sensor wire harness connectors.
  58. Install the left and right brake calipers
    GC0146098Courtesy of CHRYSLER GROUP, LLC
  59. Connect the steering shaft coupler to the steering shaft (3) and install a NEW  pinch bolt (2) and tighten to 49 N.m (36 ft. lbs.).
    GC0153866Courtesy of CHRYSLER GROUP, LLC
  60. Install the ground cable (2) to the generator and tighten the nut (3) to 11 N.m (8 ft. lbs.).
  61. Connect the engine to body wire harness connector.
  62. Remove the caps and connect the transmission cooler lines to the radiator.
  63. Install the coolant recovery bottle. Refer to BOTTLE, COOLANT RECOVERY, INSTALLATION .
  64. Connect the low pressure supply and return lines by the brake booster.
  65. Connect the two heater hoses at bulk head.
  66. Remove the tape or plugs from the opened refrigerant line fittings and the compressor ports.
  67. Lubricate the NEW  seals with clean refrigerant oil and install them onto the refrigerant line fittings. Use only the specified seals as they are made of a special material for the refrigerant used in the system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  68. Connect the A/C suction line and the A/C discharge line to the A/C compressor then install the nuts and tighten to 20 N.m (15 ft. lbs.).
  69. Connect the brake booster vacuum hose.
  70. Install the lower radiator hose.
  71. Install the upper radiator hose.
  72. Install air cleaner body and turbocharger inlet hose. Refer to INSTALLATION .
  73. Install the cowl extension (1) and the side extensions. Refer to SILENCER, COWL EXTENSION, INSTALLATION .
    GC0146755Courtesy of CHRYSLER GROUP, LLC
  74. Connect the Charge Air Cooler (CAC) hose (1) to the EGR air flow control valve.
  75. Connect the resonator to turbocharger CAC hose.
  76. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
  77. Install the transmission skid plate. Refer to PLATE, SKID, TRANSMISSION .
  78. Install the front suspension skid plate. Refer to PLATE, SKID, FRONT SUSPENSION .
  79. Install the front skid plate. Refer to PLATE, SKID, FRONT .
  80. Remove the support and lower the vehicle.
  81. Install a NEW  oil filter. Refer to FILTER, ENGINE OIL .
  82. Fill engine with the recommended engine oil. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
  83. Evacuate and charge the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE .
  84. Fill the cooling system. Refer to STANDARD PROCEDURE .
  85. Connect the negative battery cable.
  86. Start engine, allow to warm, turn engine off and inspect for leaks.
    GC0174046Courtesy of CHRYSLER GROUP, LLC
  87. Install the engine cover (1).
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