01-Engine - 2.8L Diesel

2010 ENGINE
2.8L Diesel Service Information Wrangler
DESCRIPTION
DESCRIPTION
Fig. 1: 2.8L ENGINE
The 2.8L (2776cc) fourcylinder "common rail" direct injection engine is an inline overhead valve design. The
engine utilize a cast iron cylinder block. The engine has a one piece aluminum cylinder head with four valves
per cylinder and dual overhead cam shafts. The 2.8L is turbocharged, intercooled and also equipped with a
EGR cooler.
The identification stamp for the 2.8L is located on the left side of the engine block, above the starter. The
engine code label is located on the front timing cover and is the same as the engine I.D. and serial number.
There is also a fuel system label on the front timing cover used for fuel system identification during ECM
programming.
STANDARD PROCEDURE
ENGINE GASKET SURFACE PREPARATION
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Fig. 2: Proper Tool Usage For Surface Preparation
1 ABRASIVE PAD
2 3M ROLOC™ BRISTLE DISC
3 PLASTIC SCRAPER
To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of
aluminum engine components and multilayer steel cylinder head gaskets.
Never use the following to clean gasket surfaces:
Metal scraper
Abrasive pad or paper to clean cylinder block and head
High speed power tool with an abrasive pad (1), 3M Roloc™ Bristle Disc (2), or a wire brush (3)
NOTE: MultiLayer Steel (MLS) head gaskets require a scratch free sealing surface.
Only use the following for cleaning gasket surfaces:
Solvent or a commercially available gasket remover

Plastic scraper
Sealing surfaces must be free of grease or oil residue. Clean surfaces with MoparÂ® brake parts cleaner
(or equivalent)
STANDARD PROCEDURE COMPRESSION TEST
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Fig. 3: COMPRESSION TESTER
1. Warm up engine to operating temperature (approximately 80 Â°C, 176 Â°F).

2. Shut off engine
3. Disconnect fuel feed and return lines from the fuel filter
4. Operate a vacuum pump connected to the return line until no more fuel comes out
5. Remove injectors
6. Crank engine several times with the starter to eliminate combustion residues in the cylinders
7. Insert Compression Test Adapter VM.1072A into injector hole of cylinder to be tested. Install injector
retainer bolts and tighten.
8. Test compression pressure by cranking engine with starter for at least 8 revolutions.
Cylinder compression 10 Bar (44 psi)

Difference Between
Cylinders
9. Carry out test procedure at the remaining cylinders in the same way.
10. Remove Compression Test Adapter VM.1072A from cylinder head.
11. Install injectors with new high pressure fuel tubes.
REMOVAL
REMOVAL ENGINE
1. Disconnect the negative and positive battery cables.

2. Remove the battery.
3. Recover the refrigerant. Refer to Heating and Air Conditioning/Plumbing Standard Procedur e .
4. On manual transmission models, remove the shiftier level. Refer to Transmission and Transfer
Case/Manual/LEVER, Shift Removal .
5. Remove the air cleaner body. See Engine/Air Intake System/BODY, Air Cleaner Removal.
2302
Fig. 4: CAC Turbo Outlet
6. Remove the turbocharger air inlet tube at turbo.

7. Remove the right side charge air cooler hose at cooler.
8. Raise and support the vehicle. Refer to Vehicle Quick Reference/Hoisting Standard Procedur e .
9. Remove the front lower splash shield.
10. Drain the coolant. Refer to Cooling Standard Procedur e .
11. Drain the engine oil.
12. Remove the transmission skid plate.
13. Remove the catalytic converter. Refer to Exhaust System/CONVERTER, Catalytic Removal .
14. Remove the left front wheelhouse splash shield. Refer to Body/Exterior/SHIELD, Splash Removal .
Fig. 5: HEATER CORE COOLANT HOSES
15. Remove the coolant recovery bottle. Refer to Cooling/Engine/BOTTLE, Coolant Recovery Removal
.
16. Disconnect the engine harness connectors at right side firewall.
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17. Remove the coolant hoses (1) from the heater core.
18. Remove the upper radiator hose at radiator.
19. Remove the fan assembly. Refer to Cooling/Engine/F AN, Cooling Removal .
20. Remove the serpentine belt. Refer to Cooling/Accessory Drive/BELT, Serpentine Removal .
Fig. 6: Charge Outlet Hose
21. Remove the left side charge air cooler hose at EGR air flow control valve.
22. Remove the left side charge air cooler hose at cooler.
Fig. 7: GENERATOR
23. Remove the generator. Refer to Electrical/Charging/GENERA TOR Removal .
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Fig. 8: A/C COMPRESSOR
24. Remove the A/C compressor. Refer to Heating and Air Conditioning/Plumbing/COMPRESSOR, A/C
Removal .
Fig. 9: Refrigerator Lines To Condenser
25. Remove the A/C suction and liquid line from the condenser.
26. Remove the A/C suction and liquid lines from the evaporator.
27. Remove and discard gasket/Oring seals and install protective caps over openings.
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Fig. 10: Removing/Installing Lower Radiator Hose
28. Remove the lower radiator hose at radiator.
Fig. 11: POWER STEERING PUMP PULLEY
29. Remove the power steering pump pulley (1).
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Fig. 12: Power Steering Pump
30. Remove the power steering pump (1) and position aside.
31. Disconnect the oil pressure sensor harness connector.
32. Disconnect the EGR vacuum solenoid harness connector.
Fig. 13: CAMSHAFT POSITION SENSOR HARNESS CONNECTOR
33. Disconnect the Camshaft Position Sensor (CMP) harness connector (1).
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Fig. 14: INJECTOR CONNECTOR
34. Disconnect the fuel injector harness connectors.
Fig. 15: FUEL RAIL
35. Disconnect the turbocharger actuator connector.

36. Disconnect the coolant temperature sensor harness connector.
37. Disconnect the fuel pressure sensor harness connector.
38. Disconnect the fuel pressure regulator harness connector.
39. Disconnect the EGR airflow control valve harness connector.
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Fig. 16: IAT/BPS SENSOR
40. Disconnect the IAT/BPS harness connector (1).
Fig. 17: Hood Ground Strap
41. Disconnect the ground strap between the cowl and hood.
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Fig. 18: Glow Plugs
42. Disconnect the glow plug harness connectors.

43. Position aside the upper engine harness.
44. Disconnect the brake booster vacuum hose.
Fig. 19: STARTER MOUNTING 2.8L DIESEL
45. Remove the starter. Refer to Electrical/Starting/ST ARTER Removal .
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Fig. 20: Fuel Pump Return Line
46. Disconnect the fuel quantity solenoid.

47. Disconnect the fuel supply and return tubes to high pressure pump.
48. Disconnect the fuel rail return line (1).
49. Remove bolt, and the engine ground cable at engine block.
50. Remove the crankshaft position sensor. Refer to Fuel System/Fuel Injection/SENSOR, Crankshaft
Position Removal .
Fig. 21: FLEX PLATE BOLTS
51. Remove the torque converter to flex plate bolts.

52. On manual transmission models, remove the transfer skid plate.
53. On manual transmission models, remove the water and fuel separator. Refer to Fuel System/Fuel
Delivery/SEP ARATOR and FILTER, Fuel and Water Removal .
54. On manual transmission models, remove the manual transmission. Refer to Transmission and Transfer
Case/Manual Removal .
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Fig. 22: BELL HOUSING BOLTS
55. Remove the bell housing bolts.

56. Remove the transmission oil line bracket at the oil pan.
Fig. 23: ENGINE MOUNTS
57. Remove the nut from the left engine mount.

58. Remove the nut from the right engine mount.
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Fig. 24: ENGINE LIFT
59. Install the engine lift, and support the weight of the engine.
60. Remove the engine.
INSTALLATION
INSTALLATION ENGINE
Fig. 25: ENGINE LIFT
1. Install the engine.

2. Remove the engine lift.
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3. Install the right engine mount nut. Tighten nut to 54 N.m (40 ft. lbs.).
4. Install the left engine mount nut. Tighten nut to 54 N.m (40 ft. lbs.).
Fig. 27: BELL HOUSING BOLTS
5. Install the bell housing bolts:

Tighten upper bolts to 41 N.m (30 ft. lbs.).
Tighten lower bolts to 54 N.m (40 ft. lbs.).
Tighten collar bolts to 68 N.m (50 ft. lbs.).
6. Install the transmission oil line bracket at the oil pan.
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Fig. 28: FLEX PLATE BOLTS
7. On manual transmission models, install the manual transmission. Refer to Transmission and Transfer
Case/Manual Installation .
8. On manual transmission models, install the water and fuel separator. Refer to Fuel System/Fuel
Delivery/SEP ARATOR and FILTER, Fuel and Water Installation .
9. On manual transmission models, install the transfer skid plate.
10. Install the torque converter to flex plate bolts. Tighten bolts to 31 N.m (23 ft. lbs.).
Fig. 29: Fuel Pump Return Line
11. Install the crankshaft position sensor. Refer to Fuel System/Fuel Injection/SENSOR, Crankshaft
Position Installation .
12. Install the engine ground cable at engine block.
13. Connect the fuel pump return line (1).
14. Connect the fuel supply line to high pressure pump.
15. Connect the fuel quantity solenoid.
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Fig. 30: STARTER MOUNTING 2.8L DIESEL
16. Install the starter. Refer to Electrical/Starting/ST ARTER Installation .
Fig. 31: Glow Plugs
17. Connect the brake booster vacuum hose.

18. Position the upper engine wiring harness.
19. Connect the glow plug harness connectors.
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Fig. 32: Hood Ground Strap
20. Connect the ground strap between the cowl and hood.
Fig. 33: IAT/BPS SENSOR
21. Connect the IAT/BPS harness connector (1).
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Fig. 34: FUEL RAIL
22. Connect the EGR airflow control valve harness connector.

23. Connect the fuel pressure regulator harness connector.
24. Connect the fuel pressure sensor harness connector.
25. Connect the coolant temperature sensor harness connector.
26. Connect the turbocharger actuator connector.
Fig. 35: INJECTOR CONNECTOR
27. Connect the fuel injector harness connectors.
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28. Connect the Camshaft Position Sensor (CMP) harness connector (1).
Fig. 37: Power Steering Pump
29. Connect the EGR vacuum solenoid harness connector.

30. Connect the oil pressure sensor harness connector.
31. Install the power steering pump. Tighten the bolts to 33 N.m (24 ft. lbs.).
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Fig. 38: POWER STEERING PUMP PULLEY
32. Install the power steering pump pulley. Tighten bolts to 33 N.m (24 ft. lbs.).
Fig. 39: Removing/Installing Lower Radiator Hose
33. Install the lower radiator hose at radiator.
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34. Remove protective caps and lubricate install new gasket/Oring seals.
35. Install the A/C suction and liquid lines to the expansion valve. Tighten the nut to 8 N.m (70 in. lbs.).
36. Install the A/C suction and liquid line from the condenser. Tighten the nuts to 23 N.m (17 ft. lbs.).
Fig. 41: A/C COMPRESSOR
37. Install the A/C compressor. Refer to Heating and Air Conditioning/Plumbing/COMPRESSOR, A/C
Installation .
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Fig. 42: GENERATOR
38. Install the generator. Refer to Electrical/Charging/GENERA TOR Installation .
Fig. 43: Charge Outlet Hose
39. Install the left side charge air cooler hose at cooler.
40. Install the left side charge air cooler hose at EGR air flow control valve.
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Fig. 44: HEATER CORE COOLANT HOSES
41. Install the serpentine belt. Refer to Cooling/Accessory Drive/BELT, Serpentine Installation .
42. Install the fan assembly. Refer to Cooling/Engine/F AN, Cooling Installation .
43. Connect the upper radiator hose at radiator.
44. Install the coolant hoses (1) to the heater core.
45. Connect the engine harness connectors at right side firewall.
46. Install the coolant recovery bottle. Refer to Cooling/Engine/BOTTLE, Coolant Recovery Installation
.
Fig. 45: CAC Turbo Outlet
47. Install the left front wheel house splash shield. Refer to Body/Exterior/SHIELD, Splash Installation .
48. Install the catalytic converter. Refer to Exhaust System/CONVERTER, Catalytic Installation .
49. Install the transmission skid plate.
50. Install the front lower splash shield.
51. Lower the vehicle.
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52. Install the right side charge air cooler hose.
53. Install the turbocharger air inlet tube at turbocharger.
54. Install the air cleaner body. See Engine/Air Intake System/BODY, Air Cleaner Installation.
55. On manual transmission models, install the shifter lever. Refer to Transmission and Transfer
Case/Manual/LEVER, Shift Installation .
56. Fill the coolant. Refer to Cooling Standard Procedur e .
57. Fill the with recommended engine oil.
58. Charge the A/C system. Refer to Heating and Air Conditioning/Plumbing Standard Procedur e .
59. Install the battery.
60. Connect the positive and negative battery cables.
61. Start the engine and check for leaks.
SPECIFICA TIONS
SPECIFICA TIONS
SPECIFICA TIONS (1 OF 2)
2.8L Engine Specifications
Engine 2.8L JK/KA/KK
Engine Type 2.8L 16 Valves
Displacement 2777 cc
Bore 94.00
Stroke 100.05
Power (VGT) JK KA KK 130 kW (177CV)@3800 RPM
Torque (ATX) JK 460 Nm @ 2000 RPM
Torque (MTX) JK 410 Nm @ 2000 2800 RPM
Cylinders 4 In line
Injection Order 1-3-4-2
Compression Ratio 17.0:1
Vacuum at idle 680 mm/HG (27.5 In/HG)
Idle Speed (ATX) 760 +/ 50 RPM
Idle Speed (MTX) 875 +/ 50 RPM
Maximum RPM in Gear 4500 RPM
Maximum RPM in neutral ATX 2800 MTX 3500
Belt tension Automatic Belt Tensioner
Thermostat opening 80Â°C +/ 2Â°C
Generator Rating Denso 12V-180A
Emissions Level EU4
Block configuration/Material Open/Cast Iron
Cylinder Head Dual Overhead Cam
Timing System Belt
Fuel System CP3.2+ 1,600 bar Fuel Pump, Piezo Injectors
Fuel Supply Electric Fuel Pump In the Fuel Tank
Electronic Control Unit EDC 16
Timing System Belt Driven DOHC Overhead Camshaft
Air Intake Dry Filter With turbocharger and Charge Air Cooler
Fuel System Direct Fuel Injection Common Rail System
Emission devices Cooled EGR (pneumatic)
Electric Intake Throttle
Fast Metallic Glow plugs
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Combustion Cycle 4 Stroke
Cylinder Compression Difference Between 10 bar (145 psi)
Cylinders
Cooling System Water Cooling
Turbocharging: Single VGT with REA
Intake Ports Aluminum heads with traditional dual side intake
and exhaust ports. One intake port is helical and the
other has a directed entry.
Crankshaft 8 Counterweights with an incorporated balance
shaft gear.
Camshafts 2 overhead camshafts with axial front bearings and
identical camshaft caps, finger followers, and
hydraulic lifters.
Intake AND Exhaust Valves Flat with fire deck face.
Intake Manifold Aluminum, with Castin EGR passages, intake
mixer, vacuum actuated EGR valve, electric intake
throttle and a Utype EGR cooler
Lubrication Pressure Lubricated By Rotary Pump
Minimum Oil Pressure (warm) 0.7 BAR at idle/2.5 BAR at 3800 RPM
Engine Rotation Clockwise Viewed From Front Cover
SPECIFICA TIONS (2 OF 2)
2.8L Engine Specifications
Cylinder Head
Cylinder head height 135.5 mm (5.334 in.)
Cylinder head flatness deformation tolerance 0.075 mm (0.003 in.)
Cylinder head gasket thickness
0 Hole 1.10 mm (0.043 in)
1 Hole 1.20 mm (0.047 in)
2 Holes 1.30 mm (0.051 in)
Intake Manifold
Intake manifold flatness deformation tolerance 0.075 mm (0.003 in.)
Exhaust Manifold
Exhaust manifold flatness deformation tolerance 0.075 mm (0.003 in.)
Tappets
Hydraulic tappet outside diameters 11.994 mm +/ 0.06 mm (0.472 in +/ 0.002)
Valves -
Intake valve face angle 45Â°30'
Exhaust valve face angle 45Â°30'
Intake Valve Head Diameter 32 mm (1.25 in.)
Exhaust Valve Head Diameter 29.4 mm (1.15 in.)
Intake Valve Stem Diameter 5.97 mm (0.235 in.)
Exhaust Valve Stem Diameter 5.96 mm (0.235 in.)
Intake Valve Guide Stem Clearance
Min 0.030 mm (0.0012 in.)
Max 0.060 mm (0.0024 in.)
Exhaust Valve Guide Stem Clearance
Min 0.040 mm (0.0016 in.)
Max 0.070 mm (0.0028 in.)
Valve Springs -
Free Length 50.8 mm (2 in.)
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Closed Valve 38 mm (1.49 in.)
Opened Valve 29 mm (1.14 in.)
Camshafts
Camshaft End Play
Max 0.350 mm (0.013 in.)
Min 0.150 mm (0.006 in.)
Outer Journal Diameter (at crankshaft) 25.95 mm +/ 0.01 mm (1.021 mm +/.0004 in)
Inner Journal Diameter (at cylinder head) 26.00 mm + 0.015 mm (1.027 mm/.0006 in)
Crankshaft Journal Clearance.
Max 0.075 mm (0.003 in.)
Min 0.030 mm (0.0012 in)
Connecting Rods
Connecting Rod Diameter (Small End) 32 mm (1.26 in.)
Connecting Rod Diameter (Large End) 57.563 mm (2.266 in.)
Piston Pin
Diameter 32 mm (1.26 in.)
Length 70.7 mm 71.00 mm (2.78 in 2.79 in.)
Crankshaft
End Play 0.1 mm 0.33 mm (0.004 in. 0.013 in.)
Bearing Selection. Refer to Standard Procedur e and Engine/Engine Block/CRANKSHAFT
Installation .
Engine Block
Cylinder Bore Internal Diameter 94 mm (3.700 in.)
Cylinder Bore OutOfRound 0.007 mm (0.0003 in.)
Oversized Piston +0.40 mm (+0.015 in.)
Fuel System
Injection Pressure CRS 3.0 1600 Bar
High Pressure Pump CP3.2+
ECU EDC16CP31
Injectors Piezo CRI 3.0
Glow Plugs
Make/Type Bosch/GLP2
Voltage 4.4V
Lubrication System
Oil Pump Outer Rotor End Play
Min 0.01 (0.0004 in.)
Max 0.09 (0.0036 in.)
Oil Pump Inner Rotor End Play
Max 0.01 mm (0.0004 in.)
Min 0.09 mm (0.0036 in.)
Oil Pump Outer Rotor to Body Diameter Clearance
Max 0.130 mm (0.052 in.)
Min 0.230 mm (0.0091 in)
Oil Pressure Relief Valve
Opening Pressure 5 Bar
Oil Pressure Valve Spring Free Length 46.8 mm (1.84 in)
Minimum Oil Pressure (Warm) -
at Idle 0.7 Bar
at 3800 RPM 2.5 Bar
Cooling System
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Thermostat Opening Temperature 80Â°C (176Â°F)
Pressure Cap Setting 1.2 Bar
Engine Oil
Specification
Refer to Vehicle Quick Reference/Capacities and Recommended Fluids Description .
Coolant
Specification. Refer to Vehicle Quick Reference/Capacities and Recommended Fluids Description .
CYLINDER HEAD GASKET SELECTION

Cylinder Head Gasket Selection
- Millimeters Inches
DISTANCE FROM PISTON AT TDC TO 0.300 0.399 0.0119 0.0158
CYLINDER BLOCK
CYLINDER HEAD GASKET THICKNESS 1.10 0.0434
PISTON CLEARANCE 0.700-0.800 0.0276 0.0315
- -
CYLINDER BLOCK
- -
CYLINDER BLOCK
TORQUE
ENGINE BLOCK
DESCRIPTION N.m Ft. Lbs. In. Lbs.
Air Temp/Pressure sensor 12 - 106
Balance Shaft 33 24 -
Connecting Rod Caps See Engine/Engine Block/ROD, Piston and Connecting Installation.
Dipstick Tube (block) 11 - 97
Dipstick Tube (sump) 11 - 97
Engine Block Plug 30 22 -
Engine Mount Bolts 54 40 -
Lower Oil Pan See Engine/Lubrication/P AN, Oil Installation.
Main Bearing Caps See Engine/Engine Block/CRANKSHAFT Installation.
Oil Cooler 12 - 106
Oil Cooler Coolant Adapter 11 - 97
Tube at Oil Filter Housing
Bolt
Oil Cooler Coolant Tube Bolt 15 - 133
Oil Drain Plug 54 40 -
Oil Filter Cap 25 18 -
Oil Filter Housing 33 24 -
Oil Jet 11 - 97
Oil Pickup Tube 15 - 133
Oil Pressure Sensor 14 - 124
Upper Oil Pan (M6 bolt) 15 - 133
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Upper Oil Pan (M8 bolt) 32 24 -
CYLINDER HEAD
Camshaft Cap 11 - 97
Camshaft Position Sensor 11 - 97
Camshaft Sprocket 80 59 -
Cylinder Head Bolt See Engine/Cylinder Head Installation.
Cylinder Head Cover 11 - 97
EGR Air Flow Control 11 - 97
Valve Assembly
Exhaust Manifold 36 27 -
Front Camshaft Journal 11 - 97
Fuel injector 33 24 -
Fuel Injector Fuel Lines at 5 + 75Â° - 44 + 75Â°
Fuel Rail
Fuel Injector lines at the 28 20 -
injector
Fuel Rail 24 18 -
Glow Plugs 14 - 124
High Pressure Fuel Line 15 - 133
Bracket bolt
High Pressure Fuel Feed
5 + 75Â° - 44 + 75Â°
Line at Fuel Rail
High Pressure Fuel Feed 28 20 -
Line at the High Pressure
Pump
Intake Manifold Nuts 25 18 -
Turbocharger Nuts 32 24 -
Turbocharger Brace Bolts 32 24 -
Turbocharger Oil Feed Line 32 24 -
at the Engine Block
Nipple at the Engine Block
Banjo Bolt at the
Turbocharger
Turbocharger Oil Return 15 - 133
Line
Vacuum Tube 11 - 97
FRONT ENGINE
Accessory Belt Tensioner 45 33 -
Bolt
Accessory Drive Idler 45 33 -
Pulley Bolt
Camshaft Position Sensor 11 - 97
Crankshaft Pulley 32 24 -
Crankshaft Sprocket 100 + 120Â° 74 + 120Â° -
Front Cover 33 24 -
Front Engine Lifting 45 33 -
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Bracket
Fuel Quantity Solenoid 11 - 97
High Pressure Fuel Pump 24 18 -
Nuts
High Pressure Fuel Pump 88 65 -
Sprocket Nut
Inner Front Cover 11 - 97
Outer Front Cover (lower) 11 - 97
Outer Front Cover (upper) 11 - 97
Timing Belt Tensioner 28 21 -
Water Pump 32 24 -
REAR ENGINE
Crankshaft Sensor 11 - 97
CKP Cover Plate 15 - 133
Flex Plate (ATX) See Engine/Engine Block/FLEXPLATE Installation.
Rear Cover 15 - 133
Rear Lifting Bracket 45 33 -
Trans Adapter Plate (allen 79 58 -
bolts)
Trans Adapter Plate (hex 45 33 -
bolt)
ACCESSOR Y DRIVE
A/C Compressor 32 24 -
A/C Compressor/Generator 45 33 -
Bracket
A/C Compressor/Generator 25 18 -
Bracket Support
Generator 33 24 -
Power Steering Pump 33 24 -
Power Steering Pump Pulley 33 24 -
SPECIAL TOOLS
SPECIAL TOOLS
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Fig. 46: LOCKING TOOL VM.1055
Fig. 47: REMOVER, SEAL VM.1058
Fig. 48: BALANCE SHAFT LOCK PIN VM.10012
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Fig. 49: 2.8L PISTON INSTALLER VM.1082
Fig. 50: FRONT AND REAR SEAL TOOL VM.9990
Fig. 51: ADAPTER, COMPRESSION TEST VM.1072A
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Fig. 52: INSTALLER/GUIDE SEAL 9937 1, 99372
Fig. 53: INSTALLER, SEAL VM.1057
Fig. 54: CAMSHAFT TIMING TOOL VM.9991
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Fig. 55: CRANKSHAFT LOCKING TOOL VM.9992
Fig. 56: CRANKSHAFT SEAL INSTALLER VM.9993
Fig. 57: Valve Spring Compressor MD998772A
Fig. 58: Valve Spring Adapter MD998772A15
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Fig. 59: EXHAUST MANIFOLD ALIGNMENT TOOL VM.10334
CYLINDER HEAD
DESCRIPTION
DESCRIPTION
Fig. 60: Cylinder Head Bolt Torque Sequence
The 2.8L aluminum, overhead valve cylinder head is torqued in a cross pattern. The cylinder head itself is not
resurfaceable.
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Fig. 61: MLS GASKET
1. The cylinder head uses a selectable Multilayered Steel gasket that is available in three sizes.
STANDARD PROCEDURE
VALVE SEALS - IN VEHICLE
Fig. 62: COMPRESSION TESTER
1. Disconnect the negative battery cable.

2. Remove the cylinder head cover. See Engine/Cylinder Head/COVER(S), Cylinder Head Removal.
NOTE: Rocker arms and lifters must be kept in order of removal and stored in the
up right position.
3. Position the rocker arms aside. See Engine/Cylinder Head/ROCKER ARM, Valve Removal.
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4. Install the Compression Tester Adaptor Tool VM.1072A, into the injector hole and retain with an injector
hold down (2) bolt.
5. Prepare Valve Spring Compressor Tool MD998772A for usage by inverting the tool to cylinder head
holding screws so that the thread size matches the cylinder head.
6. Install Valve Spring Compressor Tool MD998772A onto cylinder head and using Valve Spring Adaptor
MD998772A15, place the adaptor over the valve spring.
7. Connect a regulated air supply (3) to Compression Test Adapter Tool VM.1072A and pressurize the
cylinder.
8. Place shop towels around the working area of the cylinder head to prevent valve locks from accidently
entering the engine.
Fig. 63: MD998772A15 ADAPTOR
1 MD998772A15 ADAPTOR
2 VALVE SPRING
3 VM.1072A COMPRESSION TESTER ADAPTOR
9. Using Valve Spring Adaptor MD998772A15 (1), collapse the valve spring (2) and remove the locks.
10. Remove the valve spring (2) assembly.
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Fig. 64: VALVE SEAL
1 VALVE SEAL
11. Remove the valve seal (1).

12. Repeat this procedure for all cylinders.
VALVE SERVICE
This procedure is done with the engine cylinder head removed from the block.
DISASSEMBLY
1. Remove the engine cylinder head from the cylinder block. See Engine/Cylinder Head Removal.
2. Use Valve Spring Compressor Tool and compress each valve spring.
3. Remove the valve locks, retainers, and springs.
4. Use a smooth stone or a jewelers file to remove any burrs on the top of the valve stem, especially around
the groove for the locks.
5. Remove the valves, and place them in a rack in the same order as removed.
VALVE CLEANING
1. Clean all carbon deposits from the combustion chambers, valve ports, valve stems, valve stem guides and
head.
2. Clean all residue and gasket material from the engine cylinder head machined gasket surface.
INSPECTION
Fig. 65: VALVE SPRING CHART
VALVE SPRING CHART

LOAD Kg HEIGHT mm STATE
P1 0.00 H1 50.8 FREE LENGTH
P2 182-5 H2 38.0 VALVE CLOSED
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+10%
P3 395Â H3 29.0 VALVE OPEN
±5%
1. Inspect for cracks in the combustion chambers and valve ports.

2. Inspect for cracks on the exhaust seat.
3. Inspect for cracks in the gasket surface at each coolant passage.
4. Inspect valves for burned, cracked or warped heads.
5. Inspect for scuffed or bent valve stems.
6. Replace valves displaying any damage.
7. Check valve spring height .
VALVE SEAT REFACING
1. Install a pilot of the correct size in the valve guide bore. Reface the valve seat to the specified angle with
a good dressing stone. Remove only enough metal to provide a smooth finish.
2. Use tapered stones to obtain the specified seat width when required.
VALVE GUIDES
Fig. 66: VALVE HEIGHT
1. Valve Guides height requirement.

2. Measurement A and B: 13.50 mm 14.00 mm. (0.570 in 0.590 in)
VALVE STEM-TO-GUIDE CLEARANCE MEASUREMENT
1. Measure and record internal diameter of valve guides. Valve guide internal diameter is 6.0 to 6.012 mm
(0.2362 to 0.2366 in.).
2. Measure valve stems and record diameters. Intake valve stem diameter 5.952 to 5.97 mm (0.2343 to
0.2350 in). Exhaust valve stem diameter 5.942 to 5.96 mm (0.2339 to 0.2346 in).
3. Subtract diameter of valve stem from internal diameter of its respective valve guide to obtain valve stem
clearance in valve guide. Clearance of inlet valve stem in valve guide is 0.03 to 0.06 mm (.0011 to .0023
in). Clearance of exhaust valve stem in valve guide is 0.04 to 0.07 mm (.0015 to .0027 in).
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4. If valve stem clearance in valve guide exceeds tolerances, new valve guides must be installed.
REMOVAL
REMOVAL - CYLINDER HEAD
1. Disconnect the battery cables.

2. Remove the battery.
3. Remove the intake manifold. See Engine/Manifolds/MANIFOLD, Intake Removal.
4. Remove the exhaust manifold. See Engine/Manifolds/MANIFOLD, Exhaust Removal.
5. Remove the camshafts. See Engine/Cylinder Head/CAMSHAFT, Engine Removal.
Fig. 67: INNER FRONT COVER
6. Remove the inner timing belt cover.
Fig. 68: ROCKER ARM AND LIFTER ASSEMBLY
2339
NOTE: Observe the position of the rocker arms and lifters. Always return the
rocker arms and lifters to their original location.
7. Remove the rocker arms (1) and hydraulic lifters (2).

8. Remove the cylinder head bolts.
9. Remove the cylinder head.
CLEANING
CLEANING
Fig. 69: ENGINE BLOCK
Thoroughly clean the engine cylinder head and cylinder block mating surfaces. Clean the intake and exhaust
manifold and engine cylinder head mating surfaces. Remove all gasket material and carbon. See Engine
Standard Procedur e.
Check to ensure that no coolant or foreign material has fallen into the tappet bore area.
Remove the carbon deposits from the combustion chambers and top of the pistons.
INSPECTION
INSPECTION
2340
Fig. 70: Cylinder Head Flatness (1 Of 2)
1 FEELER GAUGE
2 STEEL STRAIGHT EDGE
CAUTION: The cylinder head surface and straight edge must be absolutely clean before
the flatness measurement is taken. DO NOT check flatness across the
combustion chamber area or on the marks left by the gasket stopper.
Use a cleaned straight edge (2) and feeler (1) gauge to check the flatness. Lie the straight edge (2) parallel
across the cooling ports. Measure before each combustion chamber toward the outer edge of the cylinder head,
above and below each combustion chamber, between each combustion chamber, top and bottom, on the
cylinder head and block mating surfaces. The maximum allowed warpage is 0.075 mm (0.003 in.).
Fig. 71: Cylinder Head Flatness (2 Of 2)
1 Feeler Gauge
2 Straight Edge
The minimum cylinder head thickness is 135.5 mm (5.33 in.).

2341
INSTALLATION
INSTALLATION - CYLINDER HEAD
Fig. 72: Crankshaft Locking Tool
1. Remove the crankshaft locking tool VM.9992 (1).
Fig. 73: DECK HEIGHT
2. Set the number one piston to top dead center (TDC).
2342
Fig. 74: PISTON PROTRUSION MEASUREMENT
3. Zero the dial indicator on the top of the piston at location shown (1) in illustration.
4. Use the dial indicator to measure the height of the piston at top dead center.
5. Zero the dial indicator on the top of the piston at location shown (2) in illustration.
6. Use the dial indicator to measure the height of the piston at top dead center.
7. Repeat the procedure for each cylinder.
8. Average the 4 piston protrusion readings to determine the required gasket thickness.
CYLINDER HEAD GASKET SELECTION

Cylinder Head Gasket Selection
- Millimeters Inches
DISTANCE FROM 0.300 0.399 0.0119
PISTON AT TDC TO 0.0158
CYLINDER BLOCK
CYLINDER HEAD 1.10 0.0434
GASKET THICKNESS
PISTON CLEARANCE 0.701 0.800 0.0276
0.0315
- -
DISTANCE FROM 0.400 0.499 0.0158
CYLINDER BLOCK
GASKET THICKNESS
0.0315
- -
DISTANCE FROM 0.500 0.600 0.0197
CYLINDER BLOCK
GASKET THICKNESS
0.0315
2343
9. Select the appropriate cylinder head gasket from the cylinder head gasket chart.
Fig. 75: MLS GASKET
10. Install the head gasket (1).
Fig. 76: Cylinder Head Bolt Torque Sequence
11. Install the cylinder head.
NOTE: Always use new cylinder head bolts whenever the existing bolts have
been removed.
12. Install the cylinder head bolts. Using the pattern shown in illustration, tighten bolts to 30 N.m (22 ft.
lbs.).
Repeat the illustrated pattern, turning the bolts an additional 85 degrees.
2344
Repeat the illustrated pattern, turning the bolts an additional 85 degrees.
Repeat the illustrated pattern, turning the bolts an additional 85 degrees for a total of 255 degrees.
13. Install the hydraulic lifters (2) and rocker arms (1). Make sure to return the lifters and arms to their
original position.
14. Install the inner front cover. Tighten the bolts to 11 N.m (97 in. lbs.).
15. Install the camshafts. See Engine/Cylinder Head/CAMSHAFT, Engine Installation.
16. Install the exhaust manifold. See Engine/Manifolds/MANIFOLD, Exhaust Installation.
17. Install the intake manifold. See Engine/Manifolds/MANIFOLD, Intake Installation.
18. Connect the battery.
CAMSHAFT , ENGINE
2345
Description
DESCRIPTION
Fig. 79: CAMSHAFTS
The camshafts are made of cast iron with eight machined lobes and four bearing journals.
Fig. 80: CAMSHAFT OIL SEAL
1. The exhaust camshaft (1) incorporates the CMP sensor reluctor wheel. The intake camshaft uses a
camshaft seal (2).
2346
Fig. 81: Camshaft Timing Dots
2. The dots on the back of the camshaft gears are for initial timing only. These dots are for timing the
camshafts to each other. To correctly set engine timing, the camshafts must be set to 90Â° ATDC. The
Camshaft Locking Tool VM.9991 is used to correctly set the camshafts to their proper location.
Removal
REMOVAL - CAMSHAFT
Fig. 82: CAMSHAFT TIMING SPROCKET

2. Remove the intake camshaft sprocket (2). See Engine/Valve Timing/SPROCKET(S), Timing Belt and
Chain Removal.
2347
Fig. 83: Upper And Lower Front Covers
3. Remove the cylinder head cover (7). See Engine/Cylinder Head/COVER(S), Cylinder Head
Removal .
Fig. 84: Front Camshaft Bearing Journal
4. Remove the front cam bearing journal (2).
2348
Fig. 85: CAMSHAFT OIL SEAL
5. Remove the intake camshaft oil seal (2).
Fig. 86: Identifying Camshaft Cap & Cylinder Head (Intake Side) Markings
NOTE: Observe the position marks on the cylinder head and camshaft cap as a
reference to its original location. The illustration is an example of the
camshaft markings.
2349
Fig. 87: CAMSHAFTS
NOTE: Intake and exhaust manifolds removed for clarity.
6. Using a circular pattern, remove bolts and the camshaft bearing caps.
7. Remove the camshafts.
Installat ion
INSTALLATION - CAMSHAFT
1. Lubricate the camshaft journals with MoparÂ® Engine Oil Supplement, or equivalent.
NOTE: The dots on the back of the camshaft gears are for initial timing only.
These dots are for timing the camshafts to each other. To correctly set
engine timing, the camshaf
2350 st be set to 90Â° ATDC. The camshaft
engine timing, the camshafts must be set to 90Â° ATDC. The camshaft
locking tool is used to correctly set the camshafts to their proper location.
2. Make sure that the three small orientation dots marks on the back side of the camshaft gears are
horizontal and facing each other.
3. Carefully install camshafts onto the camshaft journals.
Fig. 89: Identifying Camshaft Cap & Cylinder Head (Exhaust Side) Markings
4. The cylinder head and camshaft caps have markings to identify each cap to its correct location. In the
illustration, 1S (1) is marked on the exhaust side camshaft cap and 1S (2) is the mark on the exhaust side
of the cylinder head. It is critical that all of the camshaft caps are returned to their correct locations.
Fig. 90: Identifying Camshaft Cap & Cylinder Head (Intake Side) Markings
5. The cylinder head and camshaft caps have markings to identify each cap to its correct location. In the
illustration, 1A (1) is marked on the intake side camshaft cap and 1A (2) is the mark on the intake side of
the cylinder head. It is critical that all of the camshaft caps are returned to their correct locations.
2351
Fig. 91: Identifying Camshaft Bolts
NOTE: Whenever the camshaft caps are removed, always replace the bolts.
6. The camshaft bolts have 2 different bolt sizes.

Bolts A are M6 35 mm.
Bolts B are M6 45 mm.
Fig. 92: Identifying Camshaft Bolt Tightening Sequence
7. Using new bolts and the tightening sequence shown in illustration, install the camshaft bolts and tighten
bolts in one turn increments until finger tight.
2352
Fig. 93: Applying Sealant To Front Camshaft Bearing Journal
NOTE: Be careful not to get ant LoctiteÂ® 510 onto the camshaft journal.
8. Apply a thin bead of LoctiteÂ® 510 to the front camshaft bearing journal (2) in the location shown in
illustration (1).
9. Install the front camshaft bearing journal and tighten the new bolts finger tight.
Fig. 94: Camshaft Cap Bolt Torque Sequence
10. Using the sequence shown in illustration, tighten the camshaft cap bolts to 11 N.m (97 in. lbs.).
2353
Fig. 95: Camshaft Marks At 90 Degrees ATDC
11. Rotate the camshafts so that the camshaft locking tool VM.9991 fits into place.
Fig. 96: INSTALLING CAMSHAFT LOCK TOOL
12. Install the Camshaft Locking Tool VM.9991 (1) onto the camshaft position sensor tone wheel (2).
2354
Fig. 97: CAMSHAFT LOCKING TOOL INSTALLED
13. When the Camshaft Locking Tool VM.9991 is bolted in place, the camshafts are locked at 90 degrees
ATDC.
Fig. 98: CAMSHAFT OIL SEAL INSTALLATION
14. Using the Seal Installer 99371 and 99372 (1), install the intake camshaft oil seal.
2355
15. Install the cylinder head cover (7). See Engine/Cylinder Head/COVER(S), Cylinder Head
Installation .
16. Install the camshaft sprocket (2). See Engine/Valve Timing/SPROCKET(S), Timing Belt and Chain
Installation .
17. Connect the negative battery cable.
CHECKING CAMSHAFT END PLAY
2356
Fig. 101: CAMSHAFTS
1. After camshafts are properly installed in cylinder head cover check end play of camshafts with a dial
indicator. The end play should be between 0.10 mm 0.55 mm.
NOTE: If the camshaft endplay is not within specification, replace the cylinder
head.
2. Measure the camshaft end play with a dial indicator. The end play should be between 0.15 mm 0.35 mm
(0.006 in 0.014 in.).
COVER(S), CYLINDER HEAD

Description
DESCRIPTION
The cylinder head cover is made of an injection molded composite. The cylinder head cover also incorporates a
oil drain back hole for the crankcase ventilation (CCV) system.
Removal
REMOVAL
2357
Fig. 102: Crankcase Vent Hose & Oil Separator
2. Disconnect the crankcase vent hose (1) from the oil separator (2).
Fig. 103: Fuel Return LinesTop
3. Disconnect the fuel injector return line (1) from the fuel injectors.
4. Disconnect the vacuum line from the EGR solenoid to EGR valve (2).
5. Disconnect the EGR solenoid electrical connector.
2358
Fig. 104: Vacuum Supply Tube
6. Disconnect the vacuum line (1) to the EGR solenoid.

7. Remove the retaining nuts and position aside the vacuum line (2).
Fig. 105: Fuel Injector Harness
8. Disconnect the fuel injector harness connectors from the fuel injectors (1).
2359
Fig. 106: FUEL RAIL
9. If necessary, loosen the fuel rail nuts.

10. Remove the fuel injector fuel lines (3) from the fuel injectors and the fuel rail. Install protective caps onto
the fuel injector.
Fig. 107: Diesel Fuel Injectors
11. Remove the fuel injectors (1).
2360
Fig. 108: Upper Cover Bolts
NOTE: The upper cover bolts are encased in a collar which does not permit them
to be removed.
12. Loosen the upper front timing cover bolts (1).
13. Loosen the fasteners (8) and the cylinder head cover (7).
Installat ion
INSTALLATION
1. Clean and inspect the gasket surface of the cylinder head and the cylinder head cover gasket. Replace
cylinder cover gasket if necessary.
2361
2. Install the cylinder head cover (7). Tighten to 11 N.m (97 in. lbs.).
Fig. 111: Upper Cover Bolts
3. Tighten the upper front timing cover bolts (1) to 11 N.m (97 in. lbs.).
2362
Fig. 112: Diesel Fuel Injectors
4. Install fuel injectors, washer, and injector retainer claw.

5. Install the injector clamp bolts. Tighten injector clamp bolts to 33 N.m (24 ft. lbs.).
Fig. 113: FUEL RAIL
6. Remove the protective caps and loosely install the high pressure fuel lines (3) onto the fuel injectors and
the fuel rail.
7. If necessary, tighten the fuel rail nuts to 24 N.m (18 ft. lbs.).
8. Tighten the fuel lines (3) at the fuel injector to 28 N.m (20 ft. lbs.).
9. Tighten the fuel lines from the injectors to the fuel rail to 5 N.m (44 in. lbs.), plus an additional 75Â°.
2363
Fig. 114: Fuel Injector Harness
10. Connect the fuel injector harness connectors (1) to the fuel injector.
Fig. 115: Vacuum Supply Tube
11. Install the vacuum line (2) and tighten the retaining nuts.
12. Connect the vacuum line (1) to the EGR solenoid.
2364
Fig. 116: Fuel Return LinesTop
13. Connect the EGR solenoid electrical connector.

14. Connect the vacuum line from the EGR solenoid to EGR valve (2).
15. Connect the fuel injector return lines (1) to the fuel injectors.
16. Connect the crankcase vent hose (1) to the oil separator (2).
LIFTER(S), HYDRAULIC
Description
DESCRIPTION
2365
Valve lash is controlled by hydraulic tappets (2) located inside the cylinder head, in tappet bores below the
camshafts.
Removal
REMOVAL

NOTE: Always return the hydraulic lifters to their original location in the cylinder
head.
3. Remove the rocker arms (1) and hydraulic lifters (2).

2366
Inspection
INSPECTION
Clean each lifter assembly (1) in cleaning solvent to remove all varnish and sludge deposits. Inspect for
indications of scuffing on the side and base of each lifter body.
Installat ion
INSTALLATION
1. Install the rocker arms (1) and hydraulic lifters (2) into their original locations.
2367
ROCKER ARM, VALVE
Description
DESCRIPTION
The rocker arms (1) are made of stamped steel and serviced as an assembly along with the lifter.
The rocker arms (1) are used as a link between the camshaft and valves. As the camshaft rotates, the lobes of
the camshafts apply downward pressure on the rocker arms (1). This pressure is then applied to the hydraulic
lifter (2) which opens the valve.
Removal
REMOVAL
2368
3. Remove rocker arms (1) and lifters (2).
Installat ion
INSTALLATION
1. Clean and inspect gasket sealing surfaces.

2. Lubricate lifter ball end of lifter(s), valve(s), and rocker arm roller(s) with MoparÂ® Engine Oil
Supplement or equivalent.
3. Connect rocker arm(s) to lifter and reposition on valve(s).
SEAL(S), CAMSHAFT
Removal
REMOVAL - CAMSHAFT OIL SEAL
2369

2. Remove the intake camshaft sprocket (2). See Engine/Valve Timing/SPROCKET(S), Timing Belt and
Chain Removal.
Fig. 126: SEAL REMOVER & SEAL
3. Install the Seal Remover VM.1058 (2) into seal (1) as shown in illustration.
2370
Fig. 127: Identifying Seal Remover Handle, Seal Remover & Intake Camshaft Oil Seal
4. Position the Seal Remover Handle VM.1058 (1) onto Seal Remover VM.1058 (2) and remove the intake
camshaft oil seal (3).
Installat ion
INSTALLATION - CAMSHAFT OIL SEAL
Fig. 128: CAMSHAFT OIL SEAL INSTALLATION
1. Use the Seal Installer 99371 and 99372 (1) to install the intake camshaft oil seal.
2371
2. Install the camshaft sprocket (2). See Engine/Valve Timing/SPROCKET(S), Timing Belt and Chain
Installation .
ENGINE BLOCK
DESCRIPTION
DESCRIPTION
Fig. 130: ENGINE BLOCK
The 2.8L CRD Diesel engine uses a cast iron engine block. The cylinder block has increased stiffness that
reduces structural flexing and a fractured connecting rod cap design that can not distort connecting rod cap fit.
2372
STANDARD PROCEDURE
BEARING SELECTION CHARTS
CONNECTING ROD BEARINGS LARGE END

Connecting Rod Bearing Half Connecting Rod Journal Diameter Crankshaft
Journal Diameter
Connecting Rod
Large End
- - D C B A
53.929 53.936 53.936 53.942 53.942 53.948 53.948 53.955
Upper Bearing Blue Blue Red Red
A Shell
57.563 57.568 Lower Bearing Yellow Blue Blue Red
Shell
-
Upper Bearing Yellow Blue Blue Red
B Shell
57.568 57.573 Lower Bearing Yellow Yellow Blue Blue
Shell
-
C Upper Bearing Yellow Yellow Blue Blue
57.573 57.578 Shell
Lower Bearing Green Yellow Yellow Blue
Shell
-
D Upper Bearing Green Yellow Yellow Blue
57.578 57.583 Shell
Lower Bearing Green Green Yellow Yellow
Shell
CRANKSHAFT BEARINGS
Cylinder Block Bearing Half Crankshaft Main Journal Diameter
Seat Diameter
- - D C B A
64.974 64.981 64.981 64.987 64.987 64.993 64.993 65.000
A Upper Bearing Blue Blue Red Red
69.000 69.005 Shell
Lower Bearing Yellow Blue Blue Red
Shell
-
B Upper Bearing Yellow Blue Blue Red
69.005 69.010 Shell
Lower Bearing Yellow Yellow Blue Blue
Shell
-
C Upper Bearing Yellow Yellow Blue Blue
69.010 69.015 Shell
Lower Bearing Green Yellow Yellow Blue
Shell
-
D Upper Bearing Green Yellow Yellow Blue
69.015 69.020 Shell
2373
Lower Bearing Green Green Yellow Yellow
Shell
BEARING(S), CONNECTING ROD

Removal
REMOVAL - CONNECTING ROD BEARINGS
Fig. 131: CONNECTING ROD IDENTIFICATION
1 CONNECTING ROD PAWL

2 CONNECTING ROD
3 PAINTED CYLINDER IDENTIFIER
4 CONNECTING ROD BEARINGS
5 BOLTS
1. Remove the balance shaft module. See Engine/Engine Block/MODULE, Balance Shaft Removal.
2. Remove the connecting rod bearing caps (1) one at a time and discard bolts (5).
3. Carefully remove the upper half and lower half of bearing (4) from the connecting rod (2).
Installat ion
INSTALLATION - CONNECTING ROD BEARINGS
2374
Fig. 132: CONNECTING ROD SIZE
1. Each connecting rod has its own letter class (1) to a specific connecting rod journal diameter.
Fig. 133: MAIN BEARING SIZE MARK ON CRANK
2. To determine the correct bearing size for each cylinder. Each connecting rod letter class must be matched
with the crankshaft letter class (2) with the bearing selection chart to determine the correct bearing color
for each cylinder. The letters stamped into the crankshaft (2) are in the same order as the cylinders. The
first letter corresponds to the first cylinder, the second to the second, etc. See bearing selection chart. See
Engine/Engine Block Standard Procedur e.
2375

2 CONNECTING ROD
BOLTS
CAUTION: Connecting rod bolts must be replaced when disassembled. When

assembling the connecting rod (2), be sure that the connecting rod pawl
(1) on each of the connecting rod caps is facing the rear (fly wheel) side of
the engine.
NOTE: Do Not lubricate the new connecting rod bolts. They are already coated
with a anti scuff treatment.
3. Assemble connecting rod bearings (4) and bearing caps to their respective connecting rods (2) ensuring
that the serrations on the cap and reference marks are aligned.
4. Using new connecting rod bolts, tighten the connecting rod cap bolts to 10 N.m (88 in. lbs.).
5. Without loosening connecting rod bolts, tighten all bolts to 30 N.m (22 ft. lbs.).
6. Using a torque angle gauge, tighten each bolt an additional 40 degrees.
7. Using a torque wrench, recheck all rod bolt tightening to 88 N.m (65 ft. lbs).
8. Install the balance shaft module. See Engine/Engine Block/MODULE, Balance Shaft Installation.
BEARING(S), CRANKSHAFT, MAIN

Removal
REMOVAL - CRANKSHAFT BEARINGS
2376
Fig. 135: CRANKSHAFT CAP LOCATION MARKS
1. Remove the balance shaft assembly. See Engine/Engine Block/MODULE, Balance Shaft Removal.
NOTE: Bearing caps (26) are not interchangeable and are marked to ensure
according to their locations (26) in the block (1). Upper and lower bearing
halves are NOT interchangeable, and must be installed facing in the
correct direction.
2. Identify bearing cap locations (26) before removal.
Fig. 136: CRANKSHAFT BEARING SIZE MARK
3. Remove the bearing caps (1) one at a time, and if possible, replace the crankshaft bearings (3) one at a
time. Carefully rotate upper half of bearing from between the carrier and the crankshaft (4). If the upper
half of the bearing does not easily slide out of position, the crankshaft must be removed for further
inspection. See Engine/Engine Block/CRANKSHAFT Removal.
Installat ion
INSTALLATION
2377
NOTE: The crankshaft cannot be machined, if badly worn or scored it must be
replaced.
1. Locate the crankshaft journal letter class (1) stamp on the crankshaft weight.
Fig. 138: MAIN BEARING SIZE MARK ON BLOCK
2. Locate the engine block crankshaft journal letter class stamp on the engine block (1) besides the water
pump seat.
2378
Fig. 139: CRANKSHAFT BEARING SIZE MARK
3. To determine the correct crankshaft journal size, each cylinder block seat diameter letter class must be
matched with the crankshaft main journal diameter letter class. Both letter classes stamped on the
cylinder block as well as on the crankshaft weight are in a progressive order starting from the front of the
engine. The first letter corresponds to the first cylinder, the second to the second, etc. Use the crankshaft
bearing selection chart to determine the half shell color. See Engine/Engine Block Standard
Pr ocedur e.
Fig. 140: Thrust Bearings & Oil Discharge Grooves Facing Toward Crankshaft
4. When installing the thrust bearings (1) make sure the oil discharge grooves (2) face towards the
crankshaft.
5. If the crankshaft was removed to install the bearings, install the crankshaft. See Engine/Engine
Block/CRANKSHAFT Installation.
6. Install the balance shaft assembly. See Engine/Engine Block/MODULE, Balance Shaft Installation.
COVER, ENGINE, FRONT

Description
DESCRIPTION
2379
Fig. 141: OIL PUMP COVER ASSEMBLY
The oil pump cover assembly on this engine is an aluminum cover that incorporates the oil pump.
Removal
REMOVAL - FRONT ENGINE COVER
Fig. 142: TIMING BELT

2. Drain the cooling system. Refer to Cooling Standard Procedur e .
3. Remove the timing belt. See Engine/Valve Timing/BEL T, Timing Removal.
2380
Fig. 143: Crankshaft Sprocket And Bolt
NOTE: The crankshaft sprocket bolt is a left handed thread.
4. Remove bolt (1), and the crankshaft sprocket (2).
Fig. 144: High Pressur e Fuel Line At Pump
5. Remove the banjo bolt and the highpressure fuel line (4) from rear of pump.
6. Remove the highpressure fuel line (2) from rear of pump.
7. Disconnect fuel quantity solenoid (1) harness connector.
2381
Fig. 145: Coolant Tube & Bolts
8. Disconnect the coolant tube hose at oil cooler and by fuel injection pump.
9. Remove bolts (2), and the coolant tube (1).
Fig. 146: Oil Pump Pickup Tube & Bolt
10. Remove the oil pump pickup tube. See Engine/Lubrication/PICK-UP , Oil Pump Removal.
2382
Fig. 147: FRONT COVER AND GASKET
11. Disconnect the vacuum hose at vacuum pump.

12. Remove the eight bolts (1), and the front cover assembly (2).
13. If necessary, using Locking Tool VM.1055 remove the high pressure fuel pump (4) sprocket (4).
14. If necessary, remove nuts and the high pressure fuel pump (3).
2383
Fig. 149: Front Cover & Vacuum Pump Check Valve
15. If necessary, remove the vacuum pump check valve.
Installat ion
INSTALLATION - FRONT ENGINE COVER
Fig. 150: Front Cover & Vacuum Pump Check Valve
1. Clean all gasket mating surfaces.

2. If necessary, install the front crankshaft oil seal. See Engine/Engine Block/SEAL, Crankshaft Oil
Installation .
3. If necessary, transfer the vacuum pump check valve (1) and securely tighten.
2384
4. If necessary, install the high pressure fuel pump (3). Tighten nuts to 24 N.m (18 ft. lbs.).
5. If necessary, using Locking Tool VM.1055, install the high pressure fuel pump sprocket (4). Tighten nut
to 88 N.m (65 ft. lbs.).
6. Install the front cover gasket (3).

7. Install the front cover assembly (2) and tighten the eight bolts (1) finger tight.
2385
Fig. 153: Front Cover Assembly Bolt Tightening Sequence
8. Using the tightening sequence shown in illustration, tighten bolts to 33 N.m (24 ft. lbs.).
9. Install the oil pump pickup tube. See Engine/Lubrication/PICK-UP , Oil Pump Installation.
2386
Fig. 155: Coolant Tube & Bolts
10. Install the coolant tube (1). Tighten bolts (2) to 15 N.m (133 in. lbs.).
11. Connect the coolant tube hose at oil cooler and by fuel injection pump.
Fig. 156: High Pressur e Fuel Line At Pump
12. Connect fuel quantity solenoid (1) harness connector.

13. Install highpressure fuel line (2) at rear of pump. Tighten line nut to 28 N.m (21 ft. lbs.).
14. Using new sealing washers, install highpressure fuel line (4) at rear of pump. Tighten banjo bolt to 28
N.m (21 ft. lbs.).
15. Install the crankshaft sprocket (2). Tighten bolt to 100 N.m (74 ft. lbs.) plus an additional 120 degrees.
2387
16. Install the timing belt. See Engine/Valve Timing/BEL T, Timing Installation.
17. Fill the cooling system. Refer to Cooling Standard Procedur e .
CRANKSHAFT
Description
DESCRIPTION
Fig. 159: CRANKSHAFT
The crankshaft for the 2.8L is a forged steel type design with five main bearing journals. The crankshaft is
located at the bottom of the engine block.
2388
Stan dar d Procedure
CHECKING CRANKSHAFT END PLAY
1. Mount a dial indicator to a stationary point at rear of engine. Locate the probe perpendicular against the
flywheel.
2. Move the crankshaft all the way to the front of its travel.
3. Zero the dial indicator.
4. Move the crankshaft all the way to the rear and read dial indicator. For crankshaft end play clearances,
see Engine Specifications.
Removal
REMOVAL
2389
1. Remove the lower oil pan. See Engine/Lubrication/P AN, Oil Removal.
2. Remove the upper oil pan. See Engine/Lubrication/P AN, Oil Removal.
4. Remove the rear crankshaft oil seal carrier. See Engine/Engine Block/SEAL, Crankshaft Oil
Removal .
5. Remove the front cover and front crank oil seal. See Engine/Engine Block/COVER, Engine Removal.
6. Remove the bearing caps from the piston rods.
7. Remove the bearing caps from the crankshaft journals.
8. Remove the crankshaft.
Installat ion
INSTALLATION
Fig. 162: Crankshaft Bolt Tightening Sequence
1. Use the crankshaft bearing selection chart for main bearing selection. Refer to Engine/Engine Block
Standard Procedur e.
2. Lubricate and install the crankshaft bearings. Make sure the thrust washer is not touching the engine
block.
3. Install the crankshaft.
2390
Fig. 163: CRANKSHAFT CAP LOCATION MARKS
4. Using new bolts, install the main bearing caps in the same location as they were removed. The notches on
the top of the bearing caps indicate their proper position. The front cap has one notch, the next cap two,
etc.
5. Using the black number bubbles in the torque pattern, tighten the crankshaft bolts to 50 N.m (36 ft. lbs.).
6. Using the white number bubbles in the torque pattern, Turn the bolts an additional 90Â°.
7. Measure the crankshaft end play. Crankshaft end play must be between 0.1 mm and 0.33 mm (0.004 in.
0.13 in.).
8. Install the connecting rod bearings.
9. Install the connecting rods. See Engine/Engine Block/ROD, Piston and Connecting Installation.
11. Install the upper oil pan. See Engine/Lubrication/P AN, Oil Installation.
12. Install the lower oil pan. See Engine/Lubrication/P AN, Oil Installation.
13. Install the front main seal carrier. See Engine/Engine Block/SEAL, Crankshaft Oil Installation.
14. Install the rear main seal carrier. See Engine/Engine Block/SEAL, Crankshaft Oil Installation.
DAMPER, VIBRATION
Removal
REMOVAL
2391
Fig. 164: Crankshaft Damper

2. Remove the accessory drive belt. Refer to Cooling/Accessory Drive/BELT, Serpentine Removal .
3. Remove the bolts (1) and the vibration damper (2).
Installat ion
INSTALLATION
Fig. 165: Crankshaft Damper
1. Install the vibration damper (2) and retaining bolts (1). Tighten the bolts to 32 N.m (24 ft. lbs.).
2. Install the accessory drive belt. Refer to Cooling/Accessory Drive/BELT, Serpentine Installation .
3. Reconnect the negative battery cable.
FLEXPLA TE
Removal
REMOVAL
2392
Fig. 166: FLYWHEEL AND FLEX PLATE
1. Remove the transmission.

2. Paint mark the flex plate hub to flex plate relation.
3. Remove the 40 mm flex plate bolts (1) and flex plate (2).
Fig. 167: FLEX PLATE INSTALLED
4. Inspect flex plate (2) for damage.

Installat ion
INSTALLATION
2393
Fig. 168: FLEX PLATE INSTALLED
NOTE: Always use new flex plate or flywheel bolts.
1. Install the flex plate/flywheel hub and hand tighten the fasteners.
NOTE: Do not lubricate new bolts as they are already coated with an anti-scuff
treatment.
Align the flex plate to hub paint marks, where applicable.
2. Install the flex plate or flywheel bolts. Use a cross pattern to torque the bolts to 50 N.m (37 ft. lbs.).
3. Using a torque wrench fitted with a Torque Angle Gauge, (Goniometer), loosen one flex plate/flywheel
bolt at a time and tighten to 25 N.m (19 ft. lbs.) plus angle in relation to bolt length.
2394
Bolt Length Torque Angle
40 mm 60Â°
50 mm 75Â°
60 mm 90Â°
4. Install the transmission.
MODULE, BALANCE SHAFT

Description
DESCRIPTION
Fig. 170: Balance Shaft Module
The balance shaft is geardriven and is used to counteract engine vibration and roughness. The balance shaft
assembly includes balancers on two shafts. It is only serviced as an assembly. Balance shafts must be timed to
the crankshaft.
Removal
REMOVAL

2. Lock the engine 90 degrees ATDC. See Engine/Valve Timing Standard Procedur e.
3. Remove the oil pump pickup tube. See Engine/Lubrication/PICK-UP , Oil Pump Removal.
2395
Fig. 171: BALANCE SHAFT TIMING TOOL
4. Place a dowel rod (1) through the holes in the balance shaft axles to keep the balance shafts in the correct
position for reassembly.
Fig. 172: BALANCE SHAFT TOOL INSTALLED
WARNING: The balance shaft pin must be installed before the balance shaft assembly
is remove from the engine. The balance shaft pin must always remain in
the balance shaft assembly while the assembly is removed from the
engine. Do not remove the balance shaft pin until the balance shaft
assembly is completely installed on the engine.
NOTE: The crankshaft must be positioned at 90Â° after TDC in order to install the
Balance Shaft Locking Pin VM.10012 (2).
5. Insert the Balance Shaft Locking Pin VM.10012 (2) into the balance shaft assembly to lock the split gears
together.
2396
Fig. 173: Balance Shaft Housing
6. Remove bolts and the balance shaft housing (1).
Installat ion
INSTALLATION
1. The balance shafts must remain aligned by the alignment dowel rod (1) and the Balance Shaft Locking
Pin VM.10012 (2) must remain in the balance shaft assembly until the assembly is completely installed to
the engine.
2397
Fig. 175: BALANCE SHAFT TOOL INSTALLATION
2. The balance shaft pin should never be removed from the balance shaft assembly when the balance shaft
assembly is not installed in the engine. If the balance shaft was removed from the vehicle without the pin,
or the pin was removed, use the dowel to load the spring while pressing the tool into place as shown in
illustration.
Fig. 176: Balance Shaft Housing
3. Install the balance shaft housing (1) to the engine and tighten bolts finger tight.
2398
Fig. 177: BALANCE SHAFT HOUSING TORQUE SEQUENCE
4. Using the sequence shown in illustration, tighten balance shaft bolts to 33 N.m (24 ft. lbs.).
5. Remove Balance Shaft Locking Pin VM.10012 (2).

6. Remove the balance shaft assembly dowel rod (1).
2399
7. Remove the Crankshaft Locking Tool VM.9992 (1).
Fig. 180: CRANKSHAFT LOCK PLUG LOCATION
8. Install the engine block plug (1). Tighten the engine block plug to 30 N.m (22 ft. lbs.).
9. Install the upper and lower timing cover. See Engine/Valve Timing/COVER(S), Engine Timing
Installation .
10. Install the oil pump pickup tube. See Engine/Lubrication/PICK-UP , Oil Pump Installation.
11. Fill the engine oil.
PLATE, TRANSMISSION ADAPTER

Description
DESCRIPTION
2400
The transmission plate adapter is the component that allows the transmission to be bolted to the engine.
Removal
REMOVAL
Fig. 182: Transmission Adapter Plate & Bolts
1. Remove the flex plate. See Engine/Engine Block/FLEXPLATE Removal.

2. On manual transmission models, remove the flywheel. Refer to Clutch/FL YWHEEL Removal .
NOTE: Do not use any magnetic tools near the crankshaft sensor tone ring.
3. Remove bolts (1 and 2) and the transmission adapter plate (3).
Installat ion
INSTALLATION
2401
Fig. 183: Transmission Adapter Plate & Bolts
NOTE: Do not use any magnetic tools near the crankshaft tone ring.
1. Install the transmission adapter plate (3). Tighten bolts (1 and 2) finger tight.
Tighten bolts (2) to 69 N.m (51 ft. lbs.).
Tighten bolts (1) to 79 N.m (58 ft. lbs.).
2. On manual transmission models, install the flywheel. Refer to Clutch/FL YWHEEL Installation .
3. Install the flex plate. See Engine/Engine Block/FLEXPLATE Installation.
PUMP, INTERNAL VACUUM

Description
DESCRIPTION
Fig. 184: VACUUM PUMP AND OIL PUMP
The diesel engine uses a internal vacuum pump (7). This vacuum pump (7) is mounted in the engine front cover
(2). The vacuum pump is driven by a sprocket (6) on the crankshaft.
2402
Diagn osis an d Testing
VACUUM PUMP
1. Connect a vacuum gauge to the booster check valve with a short length of hose and T-fitting.
2. Start the engine allowing the engine to run for 30 seconds. Vacuum should be 18 inches HG (609
millibars). Verify the vacuum line is not leaking. If no leak is present, replace vacuum pump. See
Engine/Engine Block/PUMP, Internal Vacuum Removal.
Removal
REMOVAL
NOTE: The vacuum pump is not a serviceable item as it is part of the front cover. If
diagnosis has directed you to replace the vacuum pump, then the front cover
needs to be replaced.
1. Remove the front cover. See Engine/Engine Block/COVER, Engine Removal.

Installat ion
INSTALLATION
2403
1. Install the front cover. See Engine/Engine Block/COVER, Engine Installation.
ROD, PISTON AND CONNECTING

Description
DESCRIPTION
Fig. 187: PISTON AND CONNECTING ROD
The pistons (2) are of a free floating design. Oil jets in the engine block lubricate and cool the piston and piston
pin (3) assembly. The connecting rods (1) have a pressed in place wrist pin bushing which is lubricated by the
oil jets. Connecting rod (7) and bearing caps have cracked mating surfaces and are not interchangeable.
Stan dar d Procedure
STANDARD PROCEDURE
2404
Fig. 188: Honing Rough Table
Removal
REMOVAL
NOTE: Both the connecting rod and the connecting rod cap are paint marked to aid
during assembly. Paint marks disappear after time. If the rod and the cap are
not marked with paint, paint mark or scribe them before disassembly .
1. Disconnect negative battery cable.

2. Remove cylinder head. See Engine/Cylinder Head Removal.
3. Raise vehicle on hoist.
2405
5. Remove upper oil pan. See Engine/Lubrication/P AN, Oil Removal.
6. Remove the oil jets. See Engine/Lubrication/JET , Piston Oil Cooler Removal.
7. Remove balance shaft assembly. See Engine/Engine Block/MODULE, Balance Shaft Removal.
8. Remove top ridge of cylinder bores with a ridge reamer before removing pistons from cylinder block. Be
sur e to keep top of pistons covered during this operation.
9. Piston and connecting rods must be removed from top of cylinder block. Rotate crankshaft so that each
connecting rod is centered in cylinder bore.
NOTE: Be careful not to nick or scratch crankshaft journals
10. After removal, install bearing cap on the mating rod and mark pistons with matching cylinder number
when removed from engine block.
PISTON PIN - REMOVAL
1. Secure connecting rods (1) in a soft jawed vice.

2. Remove 2 snap rings securing piston pin (3).
3. Push piston pin (3) out of piston (2) and connecting rod (1).
PISTON RING - REMOVAL
2406
Fig. 190: PISTON RINGS REMOVAL/INSTALLATION
1. ID mark on face of top and second piston rings must point toward piston crown.
2. Using a suitable ring expander, remove top and second piston rings.
3. Remove upper oil ring side rail, lower oil ring side rail and then the oil expander from piston.
4. Carefully clean carbon from piston crowns, skirts and ring grooves ensuring the 4 oil holes in the oil
control ring groove are clear.
Inspection
INSPECTION
PISTONS

2 CONNECTING ROD
5 BOLTS
2407
1. Piston Diameter: Size: 91.912 91.928 mm (3.6185 3.6192 in.) Maximum wear limit .05 mm (.0019
in.).
2. Check piston pin bores in piston for roundness. Make 3 checks at 120Â° intervals. Maximum out of
roundness .05 mm (.0019 in.).
3. The piston diameter should be measured approximately 15 mm (.590 in.) up from the base.
4. Skirt wear should not exceed 0.1 mm (.00039 in.).
5. The clearance between the cylinder liner and piston should not exceed 0.0650.083 mm (.0025.0032 in.).
CONNECTING RODS
CAUTION: Connecting rod bolts must be replaced when disassembled. When assembling
the connecting rod (2), be sure that the connecting rod pawl (1) on each of the
connecting rod caps is facing the rear (fly wheel) side of the engine.
NOTE: Do Not lubricate the new connecting rod bolts. They are already coated with a
anti scuff treatment.
1. Assemble connecting rod bearings (4) and bearing caps to their respective connecting rods (2) ensuring
that the serrations on the cap and reference marks are aligned.
2. Tighten connecting cap bolts to 10 N.m (88 in. lbs.).
3. Without loosening connecting rod bolts, tighten all bolts to 30 N.m (22 ft. lbs.).
4. Using a torque angle gauge, tighten each bolt an additional 40Â°.
5. Recheck all bolt tightening with a torque wrench set to 88 N.m (65 ft. lbs.).
6. Check and record internal diameter of crank end of connecting rod (2).
2408
Fig. 193: Connecting Rod & Cap
CAUTION: When changing connecting rods (2), DO NOT use a stamp to mark the
cylinder location. Identify the connecting rods (2) and caps location using
a paint marker. All four must have the same weight. Replacement
connecting rods (2) will only be supplied in sets of four.
Connecting rods (2) are supplied in sets of four since they all must be of the same weight category. The weight
of the connecting rod is identified by a paint mark (1) on the connecting rod.
PISTON PINS
1. Measure the diameter of piston pin in the center and both ends. For specification, see Engine
Specifications .
Installat ion
INSTALLATION
PISTON PIN INSTALLATION
2409
1. Secure connecting rod (1) in soft jawed vice.

2. Lubricate piston pin (3) and piston (2) with clean engine oil.
3. Position piston (2) on connecting rod (1).
CAUTION: Ensure arrow on piston crown and the bearing cap numbers on the
connecting rod are on the opposite side.
4. Install piston pin (1).

5. Install snap ring in piston (2) to retain piston pin (3).
6. Remove connecting rod (1) from vice.
PISTON RINGS - INSTALLATION
Fig. 196: PISTON RINGS REMOVAL/INSTALLATION
1. Install rings on the pistons using a suitable ring expander.
2410
Fig. 197: PISTON RING GAP LOCATION
1 SECOND COMPRESSION RING GAP POSITION

2 OIL CONTROL RING GAP POSITION
3 TOP COMPRESSION RING GAP POSITION
2. Top compression ring is tapered and chromium plated. The second ring is of the scraper type and must be
installed with scraping edge facing bottom of the piston. The third is an oil control ring. Ring gaps must
be positioned, before inserting piston into the liners, as follows .
3. Top ring gap must be positioned at the #3 position (looking at the piston crown from above).
4. Second piston ring gap should be positioned at the #1 position.
5. Oil control ring gap should be positioned at the #2 position.
Fig. 198: PISTON DIRECTION
6. When assembling pistons check that components are installed in the same position as before disassembly,
determined by the numbers stamped on the crown of individual pistons. Engine cylinders are numbered
starting from gear train end of the engine. Face arrow on top of piston toward front of engine .
Therefore, the numbers stamped on connecting rod big end should face toward the injection pump side of
engine. To insert piston into cylinder use a ring compressor as shown in illustration.
INSTALLATION
2411
Fig. 199: PISTON INSTALLATION
1 PISTON
2 PISTON RING COMPRESSOR
3 ENGINE BLOCK
1. Before installing pistons, and connecting rod assemblies into the bore, be sure that compression ring gaps
are staggered so that neither is in line with oil ring rail gap.
2. Before installing the ring compressor, make sure the oil ring expander ends are butted together.
3. Immerse the piston head and rings in clean engine oil, slide the piston ring compressor, over the piston
and tighten. Ensur e position of rings does not change during this operation .
4. Face arrow on piston towards front of engine.
Fig. 200: CONNECTING ROD SIZE
5. The connecting rod bearing size (1) is stamped on the connecting rod.
2412
6. Compare the crankshaft connecting rod journal diameter (2) with the bearing selection chart to determine
the correct bearing size for each cylinder. The letters stamped into the crankshaft (2) are in the same order
as the cylinders. The first letter corresponds to the first cylinder, the second to the second, etc. See
Engine/Engine Block Standard Procedur e.
CAUTION: Care must be taken not to nick the crankshaft journal or cylinder bore
when installing the pistons.
7. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert rod and
piston into cylinder bore and guide rod over the crankshaft journal.
8. Guide the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod
into position on connecting rod journal.
NOTE: The connecting rod bolts must be replaced every time they are loosened
or removed.
9. Install connecting rod caps. Install rod bolts and tighten to 10 N.m (88 in. lbs.). Tighten bolts the next
stage to 30 N.m (22 ft. lbs.) plus 40Â°. Then with a torque wrench set to 88 N.m (65 ft. lbs.), make a
tightening check.
10. Install the oil jets. See Engine/Lubrication/JET , Piston Oil Cooler Installation.
11. Install cylinder head. See Engine/Cylinder Head Installation.
12. Install balance shaft assembly. See Engine/Engine Block/MODULE, Balance Shaft Installation.
13. Install upper oil pan. See Engine/Lubrication/P AN, Oil Installation.
15. Connect negative battery cable.
SEAL, CRANKSHAFT OIL, FRONT

Removal
REMOVAL
1. Remove the crankshaft sprocket. See Engine/Valve Timing/SPROCKET(S), Timing Belt and Chain
Removal .
2413
Fig. 202: Front Crankshaft Oil Seal
NOTE: Do not gouge or scratch the surface of the crankshaft when removing the
front crankshaft oil seal.
2. Remove the front crankshaft oil seal (1).
Installat ion
INSTALLATION
Fig. 203: Front Crankshaft Oil Seal
1. Using Seal Installer 9937, install the front crankshaft oil seal (1).
2. Install the crankshaft sprocket. See Engine/Valve Timing/SPROCKET(S), Timing Belt and Chain
Installation .
SEAL, CRANKSHAFT OIL, REAR

Description
DESCRIPTION
2414
Fig. 204: Rear Crankshaft Seal & Rear Main Oil Seal Carrier
The rear crankshaft seal consists of a seal and a seal carrier (1). The rear seal is inserted into the carrier. Once
assembled the rear main seal assembly should not be separated to reduce the possibility of damage to the
internal rear seal lip.
Removal
REMOVAL - REAR CRANKSHAFT OIL SEAL
NOTE: This must be done with either the engine or transmission removed from
vehicle.
1. On automatic transmission vehicles, remove the flex plate. See Engine/Engine Block/FLEXPLATE
Removal .
2. On manual transmission vehicles, remove the flywheel. Refer to Clutch/FL YWHEEL Removal .
3. Remove the Crankshaft Position (CKP) sensor. Refer to Fuel System/Fuel Injection/SENSOR,
Crankshaft Position Removal .
Fig. 205: Crankshaft Sensor Tone Wheel
2415
5. Remove the crankshaft sensor tone wheel before removing the rear main oil seal.
Fig. 206: REAR MAIN SEAL GASKET
6. Remove the bolts that secure the rear oil seal carrier (1) to the engine block (3).
7. Remove the rear oil seal carrier and gasket (2).
8. Remove the rear crankshaft oil seal from the rear oil seal carrier (1).
Installat ion
INSTALLATION - REAR CRANKSHAFT OIL SEAL
Fig. 207: REAR MAIN SEAL GASKET
2416
1. Clean the rear crankshaft oil seal and seal carrier sealing surfaces.
2. Position the rear main seal carrier gasket (2) onto the rear of the engine block.
3. Using Crankshaft Seal Installer VM.9993, install rear crankshaft oil seal into the rear main seal carrier
(1).
4. Install the rear main seal carrier onto the engine block (3).
Fig. 208: REAR SEAL TOOL INSTALLED
5. Loosely install the bolts that secure the rear oil seal carrier (2) to the engine block.
6. Using the Front and Rear Seal Tool VM.9990 (1) to set the depth of the rear main seal (2).
Fig. 209: REAR COVER TORQUE
7. Using the sequence shown in illustration, tighten the rear cover bolts to 15 N.m (133 in. lbs.).
2417
NOTE: Make sure the crankshaft sensor tone wheel is positioned correctly on the
crankshaft.
9. Install the Crankshaft Position Sensor (CKP). Refer to Fuel System/Fuel Injection/SENSOR,
Crankshaft Position Installation .
NOTE: If equipped, manual transmission models with start/stop, there is a special

tone wheel for this option that needs to be installed. (Refer to
Clutch/FL YWHEEL Installation ).
10. Install the crankshaft sensor tone wheel to the rear of the crankshaft.
11. On manual transmission models, install the flywheel. Refer to Clutch/FL YWHEEL Installation .
12. On automatic transmission vehicles, install the flex plate. See Engine/Engine Block/FLEXPLATE
Installation .
ENGINE MOUNTING
INSULATOR, ENGINE MOUNT, LEFT
Removal
REMOVAL - LEFT ENGINE MOUNT
NOTE: The viscous fan does not need to be totally removed from vehicle only
from the mounting drive.
2. Remove the viscous fan and position aside. Refer to Cooling/Engine/DRIVE, Fan Removal .
3. Raise and support the vehicle.
4. Remove the right side and left side lower engine mount nuts.
2418
5. Install the Engine Support Fixture 8534B.
6. Raise the engine.
7. Remove the left front tire.
8. Remove the inner fender. Refer to Body/Exterior/SHIELD, Splash Removal .
9. Remove upper nut, and the left engine mount (1).
Installat ion
INSTALLATION - LEFT ENGINE MOUNT
1. Position the left engine mount (1) and install the left upper retaining nut tight.
3. Lower the engine.
4. Remove the Engine Support Fixture 8534B.
5. Install the viscous fan. Refer to Cooling/Engine/DRIVE, Fan Installation .
6. Tighten the left upper engine mount nut to 54 N.m (40 ft. lbs.).
8. Install the left and right lower engine mount nut. Tighten nut to 54 N.m (40 ft. lbs.).
10. Install the left inner splash shield. Refer to Body/Exterior/SHIELD, Splash Installation .
11. Install the left front tire.
INSULATOR, ENGINE MOUNT, RIGHT

Removal
REMOVAL - RIGHT ENGINE MOUNT
2419
NOTE: The viscous fan does not need to be totally removed from vehicle only
from the mounting drive.
2. Remove the viscous fan and position aside. Refer to Cooling/Engine/DRIVE, Fan Removal .
4. Remove the right side and left side lower engine mount nuts.
5. Install the Engine Support Fixture 8534B.
6. Raise the engine.
7. Remove the inner fender. Refer to Body/Exterior/SHIELD, Splash Removal .
8. Remove upper nut, and the right engine mount (2).
Installat ion
INSTALLATION - RIGHT ENGINE MOUNT
2420
1. Position the right engine mount (2) and install the retaining nut finger tight.
3. Lower the engine.
4. Remove the Engine Support Fixture 8534B.
5. Install the viscous fan. Refer to Cooling/Engine/DRIVE, Fan Installation .
6. Tighten the right upper engine mount through bolts to 54 N.m (40 ft. lbs.).
8. Install the left and right lower engine mount nut. Tighten nut to 54 N.m (40 ft. lbs.).
10. Install the right inner splash shield. Refer to Body/Exterior/SHIELD, Splash Installation .
LUBRICA TION
COOLER, OIL
Description
DESCRIPTION
Engine coolant is used to cool the engine oil. A platestyle external heat exchanger is located on the oil filter
housing which is on the right side of the engine. A gasket seals the oil cooler to the oil filter housing. Replace
the gasket whenever the oil cooler is removed or replaced. The oil is fed to the oil cooler through the oil filter
housing.
Removal
REMOVAL - OIL COOLER

2. Remove the belly pan.
2421
Fig. 214: COOLANT HOSE & OIL COOLER HOUSING
5. Remove the two lower oil cooler bolts (1).
Fig. 215: ENGINE OIL COOLER & BOLTS
6. Remove the air cleaner body and turbocharger air inlet tube. See Engine/Air Intake System/BODY, Air
Cleaner Removal.
7. Remove the Charge Air Cooler (CAC) hose from (CAC).
8. Remove the (CAC) hose from turbocharger.
9. Remove the four upper bolts (1) and the engine oil cooler (2).
10. Remove and discard the Oring gasket.
Installat ion
INSTALLATION - OIL COOLER
2422
Fig. 216: ORING GASKETS
1. Clean all gasket mating surfaces.

2. Install a new Oring gaskets (1).
Fig. 217: ENGINE OIL COOLER & BOLTS
3. Install the oil cooler (2). Tighten bolts (1) to 12 N.m (106 in. lbs.).
4. Install the (CAC) hose from turbocharger.
5. Install the Charge Air Cooler (CAC) hose from (CAC).
6. Install the air cleaner body and turbocharger air inlet tube. See Engine/Air Intake System/BODY, Air
Cleaner Installation.
2423
7. Install the two lower oil cooler bolts (1). Tighten to 12 N.m (106 in. lbs.).
8. Install the belly pan.
10. Fill the engine with recommended oil.
FILTER, ENGINE OIL

Removal
REMOVAL - OIL FILTER
Fig. 219: OIL FILTER ADAPTER

2. Remove the air inlet tube from air cleaner housing and position aside.
3. Remove the oil filter housing cap (2) and the oil filter (1).
2424
Installat ion
INSTALLATION - OIL FILTER
1. Install oil filter (1) and the oil filter housing cap (2). Tighten cap to 25 N.m (18 ft. lbs.).
2. Install the air inlet tube to air cleaner housing and securely tighten clamp.
3. Fill engine with the recommended engine oil.
HOUSING, OIL FILTER

Description
DESCRIPTION
The oil filter housing is mounted on the right side of the engine. The engine oil cooler is bolted to the oil filter
housing.
Removal
REMOVAL - OIL FILTER HOUSING

3. Remove the underbody skid plate.
2425
Fig. 221: UPPER OIL DIPSTICK BOLT
6. Remove the air cleaner body and turbocharger air inlet tube. See Engine/Air Intake System/BODY, Air
Cleaner Removal.
7. Remove the upper oil dipstick bolt (1).
Fig. 222: SERPENTINE BELT TENSIONER & BOLT

9. Remove the power steering pump and position aside.
10. Remove bolt (1) and the serpentine belt tensioner (2).
2426
Fig. 223: OIL PRESSURE SWITCH
11. Disconnect the oil pressure switch harness connector (1).
12. Remove the oil filter housing cap (2) and the oil filter (1).
2427
13. Remove the coolant hose (3) from oil filter housing adapter (2).
Fig. 226: OIL FILTER HOUSING ADAPTER & BOLTS
14. Remove bolts (1) and the oil filter housing adapter (2).
2428
Fig. 227: IDENTIFYING COOLANT TUBE, ENGINE BLOCK & BOLT
15. Remove bolt (1) and the coolant tube (3) and discard Oring gasket.
Installat ion
INSTALLATION
Fig. 228: IDENTIFYING ORING SEALS
1. Install new Oring seals (1) to coolant tube.
Fig. 229: IDENTIFYING COOLANT TUBE, ENGINE BLOCK & BOLT
2. Install coolant tube (3) into engine block (2). Tighten bolt (1) to 11 N.m (97 in. lbs.).
2429
Fig. 230: ORING SEALS & OIL FILTER HOUSING
3. Install new Oring seals (1) to the oil filter housing (2) adapter.
Fig. 231: OIL FILTER HOUSING ADAPTER & BOLTS
4. Install the oil filter housing adapter (2). Tighten bolts (1) to 33 N.m (24 ft. lbs.).
2430
5. Install the coolant hose (3) to the oil filter housing adapter (2).
6. Install the oil filter (1) and the oil filter housing cap (2). Tighten to 25 N.m (18 ft. lbs.).
Fig. 234: OIL PRESSURE SWITCH
7. Connect the oil pressure switch harness connector (1).
2431
Fig. 235: SERPENTINE BELT TENSIONER & BOLT
8. Install the serpentine belt tensioner (2). Tighten bolt (1) to 45 N.m (33 ft. lbs.).
9. Install the power steering pump. Tighten bolts to 33 N.m (24 (ft. lbs.).
Fig. 236: UPPER OIL DIPSTICK BOLT
11. Install the upper oil dipstick bolt (1). Tighten bolt (1) to 33 N.m (24 ft. lbs.).
12. Install the turbocharger air inlet tube and air cleaner body. See Engine/Air Intake System/BODY, Air
Cleaner Installation.
13. Install the underbody skid plate.
15. Fill the engine with recommended oil.
JET , PISTON OIL COOLER

Description
2432
DESCRIPTION
Fig. 237: OIL JET
There are four oil jets installed in the engine block. These oil jets are used to cool and lubricate the piston
assemblies.
Removal
REMOVAL
Fig. 238: OIL JET
CAUTION: Use caution when removing and installing oil jets. Damage to oil jet nozzle
could cause severe engine damage. Care must be taken not to damage the
crankshaft tone ring when removing cylinder number four oil jet.
NOTE: To prevent damage to the oil jets, remove the oil jets before removing the
2433
pistons.

4. Remove the oil pickup tube.
7. Remove the oil jet.
Installat ion
INSTALLATION
Fig. 239: OIL JET
CAUTION: Use caution when removing and installing oil jets. Damage to oil jet nozzle
could cause severe engine damage.
1. Lubricate Oring on oil jet.

2. Install oil jet retaining bolt. Tighten bolt to 10.8 N.m (96 in. lbs.).
2434
Fig. 240: Balance Shaft Module
Fig. 241: Upper Oil Pan Bolts
4. Lubricate the oil pickup tube Oring before installation.

5. Install the oil pickup tube and tighten the bolt to 15 N.m (12 lbs. ft.).
2435
Fig. 242: OIL SUMP TORQUE SEQUENCE
6. Install the upper oil pan gasket.

7. Install the upper oil pan bolts in positions one and two, then follow the sequence shown in illustration for
the remaining bolts. Once all of the bolts are installed, tighten the m6 bolts to 15 N.m (133 lbs. in.) and
M8 bolts to 32 N.m (23 lbs. ft.).
Fig. 243: LOWER OIL PAN
8. Install the lower oil pan gasket.
2436
Fig. 244: LOWER OIL PAN TORQUE SEQUENCE
9. Install bolts one and two into the lower oil pan, then follow the sequence for the remaining bolts.
10. Tighten the oil pan bolts in sequence to 15 N.m (133 lbs. in.).
11. Turn each bolt an additional 90Â°.
12. Refill engine oil to proper level.
Fig. 245: REAM MAIN SEAL AND OIL PAN BOLTS
13. Connect the crankshaft position sensor (CKP).

14. Connect negative battery cable.
OIL
Description
2437
DESCRIPTION
Refer to the Lube and Maintenance section for oil specifications. Refer to Vehicle Quick Reference/Capacities
and Recommended Fluids Specifications .
PAN, OIL
Removal
REMOVAL - UPPER OIL PAN

2. Remove the air cleaner assembly. See Engine/Air Intake System/BODY, Air Cleaner Removal.
3. Remove the upper dip stick bolt.
5. Remove four bolts securing upper oil pan to transmission adapter plate.
7. Remove the Crankshaft Position (CKP) sensor. Refer to Fuel System/Fuel Injection/SENSOR,
Crankshaft Position Removal .
8. Remove lower dipstick bolt and the oil dipstick.
2438
9. Remove bolts and the upper oil pan.
REMOVAL - LOWE R OIL PAN

4. Using a new copper sealing washer, install and tighten oil drain plug to 54 N.m (40 ft. lbs.).
5. Remove bolts (3) and the lower oil pan (1).
6. Remove and discard the oil pan gasket.
Installat ion
INSTALLATION - UPPER OIL PAN
2439
Fig. 249: Bolt Locations
1. Clean oil pan and engine block gasket surfaces.
Fig. 250: Oil Pan Gasket Surface
2. Install the upper oil pan gasket.
2440
Fig. 251: OIL SUMP TORQUE SEQUENCE
3. Install the upper oil pan bolts in positions one and two, then follow the sequence illustrated for the
remaining bolts. Once all of the bolts are installed, tighten the M6 bolts to 15 N.m (133 in. lbs. ) and M8
bolts to 32 N.m (23 ft. lbs.).
4. Loosen all of the upper oil pan bolts and studs by 90 degrees and retighten the M6 bolts to 15 N.m (133
in. lbs.) and M8 bolts to 32 N.m (23 ft. lbs.).
5. Install the oil dip stick. Tighten lower bolt to 11 N.m (97 in. lbs.).
7. Install the Crankshaft Position (CKP) sensor. Refer to Fuel System/Fuel Injection/SENSOR,
Crankshaft Position Installation .
8. Install four bolts securing oil pan to transmission adapter plate and tighten to 69 N.m (51 ft. lbs.).
10. Install the upper dip stick bolt. Tighten upper bolt to 11 N.m (97 in. lbs.).
11. Install the air cleaner assembly. See Engine/Air Intake System/AIR CLEANER Installation.
12. Refill engine with recommended engine oil.
INSTALLATION - LOWE R OIL PAN
2441
1. Make sure that the lower oil pan sealing surface is free of oil, debris and silicone.
2. Install the new lower oil pan gasket onto the oil pan.
Fig. 253: LOWER OIL PAN TIGHTENING SEQUENCE
3. Install bolts one and two into the lower oil pan and tighten to 15 N.m (133 in. lbs.).
4. Install the remaining bolts in the sequence shown in illustration.
5. Tighten the oil pan bolts in sequence to 15 N.m (133 in. lbs.).
6. Loosen each bolt 90 degrees and retighten bolts to 15 N.m (133 in. lbs.) using the sequence shown in
illustration.
7. Fill the engine with recommended oil to proper level. Refer to Vehicle Quick Reference/Capacities and
Recommended Fluids Specifications .
2442
PICK-UP , OIL PUMP
Removal
REMOVAL - OIL PUMP PICKUP TUBE

3. Drain the oil.
5. Remove bolt (1) and the oil pump pickup tube (2) and discard Orings.
Installat ion
INSTALLATION - OIL PUMP PICKUP TUBE
2443
Fig. 256: Oil Pickup Tube & ORings
1. Lubricate and install two new Orings (2) on oil pickup tube (1).
2. Install the oil pickup tube (2). Tighten bolt (1) to 15 N.m (133 in. lbs.).
2444
4. Refill engine with recommended oil to proper level.
PUMP, ENGINE OIL

Removal
REMOVAL - OIL PUMP
NOTE: The oil pump is not a serviceable part. If oil pump failure has occurred or
diagnosis has led you to replace the oil pump, then the front cover will have to
be replaced.
2445
2. Remove the front cover. See Engine/Engine Block/COVER, Engine Removal.
Installat ion
INSTALLATION - OIL PUMP
1. Clean the gasket surfaces and sealing areas.

2. Lubricate oil pump rotor with engine oil.
3. Install front cover assembly. See Engine/Engine Block/COVER, Engine Installation.
SENSOR, OIL PRESSURE

Description
DESCRIPTION
2446
Fig. 261: OIL PRESSURE SENDING UNIT
The oil pressure sending unit uses three circuits. They are:
A signal circuit to the ECM.

A sensor ground circuit through the ECM.
A 5 volt reference circuit from the ECM.
The oil pressure sending unit returns a voltage signal back to the ECM relating oil pressure. Ground for the
sensor is supplied by the ECM.
The oil pressure switch (1) is located on the right side of the engine block. The switch screws into the engines
main oil gallery.
SEPARATOR, OIL
Removal
REMOVAL
Fig. 262: FUEL RAIL
1. Remove the engine cover. See Engine/Cylinder Head/COVER(S), Cylinder Head Removal.
NOTE: Inspect the oil drain back access hole in the intake manifold/cylinder head
cover to assure that it is free of obstruction.
2. Remove the oil separator fasteners and oil separator (4).

Installat ion
INSTALLATION
2447
Fig. 263: FUEL RAIL
NOTE: Inspect the oil drain back access hole in the intake manifold/cylinder head
cover to assure that it is free of obstruction.
1. Lubricate the oil separator orings with clean engine oil.

2. Carefully position and push down on the oil separator to seat.
3. Install the oil separator retaining fasteners. Tighten fasteners to 10.8 N.m (96 lbs. in.).
4. Install the camshaft cover. See Engine/Cylinder Head/COVER(S), Cylinder Head Installation.
VALVE, OIL PRESSURE RELIEF

Description
DESCRIPTION
Fig. 264: Oil Pressur e Relief Valve Components
2448
The oil pressure relief valve is build into the front cover (1). The oil pressure relief valve assembly (2) consists
of several components. The plunger (4) is held in place by the spring (5). The plug (6) keeps the plug and
spring in place, and the oring (7) prevents oil from leaking past the plug (6).
In the case of excessively high oil pressure, the oil pressure on the piston (4) overcomes the spring (5) pressure
and the piston is forced off its seat. When the piston is forced off its seat, a drain back passage is opened and the
excess oil pressure is vented back into the crankcase.
MANIFOLDS
MANIFOLD, EXHAUST
Removal
REMOVAL

3. Disconnect the crankcase vent hose (1) from the oil separator (2).
4. Remove the air cleaner outlet tube.
2449
Fig. 266: Turbocharger Inlet Elbow
5. Remove the air cleaner outlet tube from turbocharger inlet elbow.
6. Remove the turbocharger outlet hose from CAC inlet.
Fig. 267: Lower Transmission Fill Tube Bolt
7. If equipped, remove the lower transmission fill tube bolt (1).
Fig. 268: Transmission Fill Tube And Bolt
8. If equipped, remove the bolt (1) and the transmission fill tube (2).
9. Remove the catalytic converter. Refer to Exhaust System/CONVERTER, Catalytic Removal .
2450
Fig. 269: Turbocharger Support Bracket
10. Remove the bolts (1) from the turbocharger to engine support bracket and remove the bracket.
Fig. 270: Exhaust Manifold Heat Shield
11. Remove the bolts (1) and exhaust manifold heat shield (2).
2451
Fig. 271: TURBOCHARGER FEED LINE
12. Remove the turbocharger oil feed line.
Fig. 272: Turbocharger Oil Return Line
13. Remove the bolt (1) and turbocharger oil return line (2).
2452
Fig. 273: Turbocharger Module Connector
14. Disconnect the turbocharger module connector (1).
Fig. 274: MANIFOLD EXHAUST
NOTE: Turbocharger removed for clarity.
15. Remove the nuts and the exhaust manifold and turbocharger as an assembly.
16. If necessary, remove the turbocharger from exhaust manifold.
Installat ion
INSTALLATION
2453
Fig. 275: MANIFOLD EXHAUST
1. Clean and inspect the gasket surface of the exhaust manifold and cylinder head.
2. If necessary, clean and inspect the gasket surface of the exhaust manifold and turbocharger.
3. If necessary, using a new gasket install the turbocharger to the exhaust manifold. Tighten nuts to 32 N.m
(23 ft. lbs.).
4. Using a new exhaust manifold gasket, install the exhaust manifold and the retaining nuts finger tight.
Fig. 276: EXHAUST MANIFOLD TORQUE SEQUENCE
5. Using the tightening sequence shown in illustration, tighten the exhaust manifold nuts to 36 N.m (27 ft.
lbs.).
6. Repeat the same tightening procedure again.
2454
Fig. 277: Turbocharger Module Connector
7. Connect the turbocharger module harness connector (1).
Fig. 278: Turbocharger Oil Return Line
8. Install the turbocharger oil return line (2) and bolt (1). Tighten to 15 N.m (133 in. lbs.).
2455
Fig. 279: TURBOCHARGER FEED LINE
9. Install the turbocharger oil feed line. Tighten to 24 N.m (18 ft. lbs).
Fig. 280: Exhaust Manifold Heat Shield
10. Install the exhaust manifold heat shield (2) and the heat shield bolts (1).
2456
Fig. 281: Turbocharger Support Bracket
11. Position the turbocharger to engine support brace and install the bolts. Tighten to 32 N.m (23 ft. lbs).
Fig. 282: Transmission Fill Tube And Bolt
12. Install the catalytic converter. Refer to Exhaust System/CONVERTER, Catalytic Installation .
13. If equipped, install the transmission fill tube (2) and the bolt (1). Tighten to 11 N.m 97 in. lbs.).
2457
Fig. 283: Lower Transmission Fill Tube Bolt
14. If equipped, install the lower transmission fill tube bolt (1). Tighten to 11 N.m 97 in. lbs.).
Fig. 284: Turbocharger Inlet Elbow
15. Install the turbocharger outlet hose to CAC inlet.

16. Install the air cleaner outlet tube to turbocharger inlet elbow (1).
2458
17. Install the air cleaner outlet tube.

18. Connect the crankcase vent hose (1) to the oil separator (2).
19. Install the air cleaner assembly. See Engine/Air Intake System/BODY, Air Cleaner Installation.
MANIFOLD, INTAKE
Removal
REMOVAL - INTAKE MANIFOLD

2. Center and lock the steering wheel.
3. Remove the front lower splash shield.
4. Drain the coolant system. Refer to Cooling Standard Procedur e .
5. Disconnect the high pressure line at high pressure pump.
6. Disconnect the airflow control valve inlet hose.
7. Disconnect coolant reservoir hose from radiator.
8. Remove the coolant hoses from the coolant recovery bottle.
9. Detach the relays from coolant reservoir.
10. Remove the coolant recovery bottle.
11. Remove the A/C suction line. Refer to Heating and Air Conditioning/Plumbing/LINE, A/C Suction
Removal .
12. Remove the A/C liquid line. Refer to Heating and Air Conditioning/Plumbing/LINE, A/C Liquid
Removal .
2459
Fig. 286: GENERATOR
15. Disconnect the generator harness connector (4).

16. Remove the battery feed wire from the generator (3).
17. Remove bolts (1) and the generator.
Fig. 287: GENERATOR BRACKET
18. Remove the glow plug wire harness clip from generator mounting bracket.
19. Remove the generator brace.
20. Remove the generator mounting bracket (1).
2460
Fig. 288: Fuel Return Line & Fuel Rail
21. Disconnect the fuel return (1) line from fuel rail (2).
Fig. 289: FUEL RAIL
NOTE: High pressure fuel lines must be replaced with new lines any time they are
removed. Also, protective caps should be installed on the fuel injector any
time the lines are removed.
22. Remove bolt securing high pressure line (1) to intake manifold.
23. Remove the high pressure fuel lines (3).
24. Disconnect the fuel rail pressure sensor harness connector.
25. Disconnect the fuel rail solenoid harness connector.
26. Remove the high pressure line from fuel rail and high pressure pump.
27. Remove nuts and the fuel rail (6).
2461
Fig. 290: Glow Plugs & Wiring Harness
28. Disconnect and remove the glow plug wire harness (2).
Fig. 291: EGR COOLER
29. Disconnect the IAT/BPS harness connector.

30. Remove the coolant hoses from EGR cooler.
31. Remove the EGR cooler.
32. Disconnect the EGR valve vacuum tube.
2462
Fig. 292: PINCH BOLT AT THE COLUMN SHAFT
33. Remove the left front wheelhouse splash shield. Refer to Body/Exterior/SHIELD, Splash Removal .
NOTE: Care should be given not to allow the steering wheel to rotate after the
intermediate shaft is separated from coupler.
34. Remove the pinch bolt (2) at the upper intermediate shaft (1).
35. Separate the upper coupler on the lower shaft (3) from the upper intermediate shaft (1) and position aside.
Fig. 293: Upper Intermediate Shaft To Cowl
36. Remove the two nuts (3) securing the upper intermediate shaft to the cowl and remove the shaft (1) from
the studs (2).
2463
Fig. 294: Intake Manifold Nuts
37. Remove the intake manifold retaining nuts.
Fig. 295: Thermostat Housing & Bolts
38. Remove the thermostat housing (1).
2464
Fig. 296: Identifying Manifold Retaining Nuts, Intake Manifold & Intake Manifold Gasket
39. Remove the intake manifold (1).

40. Remove the intake manifold gasket (2).
Installat ion
INSTALLATION - INTAKE MANIFOLD
Fig. 297: Identifying Manifold Retaining Nuts, Intake Manifold & Intake Manifold Gasket
1. Clean and inspect the gasket surface of the intake manifold.

2. Clean and inspect the gasket surface of the cylinder head.
3. Install the intake manifold gasket (2).
4. Install the intake manifold (1).
2465
Fig. 298: Thermostat Housing & Bolts
5. Install the thermostat housing (1) and tighten nuts (2) finger tight.
Fig. 299: Intake Manifold Bolt Tightening Sequence
6. Install the intake manifold retaining nuts. Using the sequence shown in illustration, tighten the intake
manifold nuts to 25 N.m (18 ft. lbs.).
2466
Fig. 300: Upper Intermediate Shaft To Cowl
7. Install the intermediate shaft (1) to studs (2) at cowl.

8. Install the mounting nuts (3). Tighten to 13 N.m (115 in. lbs.).
Fig. 301: PINCH BOLT AT THE COLUMN SHAFT
NOTE: Care should be given not to allow the steering wheel to rotate after the
intermediate shaft is separated from coupler.
9. Install the lower intermediate shaft coupler (3) to upper intermediate shaft (1).
10. Install the pinch bolt (2). Tighten to 49 N.m (36 ft. lbs.).
11. Install the left front wheelhouse splash shield.
2467
Fig. 302: EGR COOLER
12. Connect the EGR valve vacuum tube.

13. Clean the gasket mating surfaces.
14. Using a new gasket, install the EGR cooler. Tighten to 15 N.m (177 in. lbs.).
15. Install the coolant hoses to the EGR cooler.
16. Connect the IAT/BPS harness connector.
Fig. 303: Glow Plugs & Wiring Harness
17. Install and connect the glow plug wire harness (2).
2468
Fig. 304: FUEL RAIL
18. Install the fuel rail (6). Tighten nuts to 24 N.m (18 ft. lbs.).
19. Connect the fuel rail solenoid harness connector.
20. Connect the fuel rail pressure sensor harness connector.
NOTE: High pressure fuel lines must be replaced with new lines any time they are
removed.
21. Position the high pressure line and install the high pressure line to fuel rail and high pressure pump.
Tighten high pressure at fuel rail to 5 N.m (44 in. lbs.) plus an additional 75 degrees, and 28 N.m (20 ft.
lbs.) at high pressure pump.
22. Remove the protective caps and install new high pressure fuel lines (3). Tighten 5 N.m (44 in. lbs.) plus
an additional 75 degrees at the fuel rail side, and 28 N.m (20 ft. lbs.) at the fuel injectors.
23. Install bolt securing high pressure line (1) to intake manifold. Tighten bolt to 15 N.m (133 in. lbs.).
Fig. 305: Fuel Return Line & Fuel Rail
24. Connect the fuel return line (1) to fuel rail (2).
2469
Fig. 306: GENERATOR BRACKET
25. Install the generator bracket (1). Tighten to 45 N.m (33 ft. lbs.).
26. Install the generator brace.
27. Remove the glow plug wire harness clip from generator mounting bracket.
Fig. 307: GENERATOR
28. Install the generator. Tighten to 33 N.m (24 ft. lbs).

29. Install the battery feed wire to the generator (3).
30. Connect the generator connector (4).
32. Install the air cleaner assembly. See Engine/Air Intake System/BODY, Air Cleaner Installation.
33. Install the A/C liquid line. Refer to Heating and Air Conditioning/Plumbing/LINE, A/C Liquid
Installation .
2470
34. Install the A/C suction line. Refer to Heating and Air Conditioning/Plumbing/LINE, A/C Suction
Installation .
35. Install the coolant recovery bottle. Tighten to 10 N.m (89 in. lbs.)
36. Attach the relays to the coolant reservoir.
37. Install the coolant hoses to the coolant recovery bottle.
38. Connect coolant reservoir hose to radiator.
39. Connect the airflow control valve inlet hose.
41. Install the front lower splash shield.
42. Remove the steering wheel lock
TURBOCHARGER SYSTEM
COOLER AND HOSES, CHARGE AIR
Removal
REMOVAL
WARNING: If the engine was just turned off, the air intake system tubes may be hot.
NOTE: When servicing the Air Charge Cooler and/or Turbocharger , the Air Charger
Hose (orange) seal located between the Air Charge Hose and Turbocharger
must be replaced.
NOTE: Note the location of the rubber charge air cooler to A/C condenser and air
charger cooler to radiator air seals. The seals are use to prevent overheating
and improve charge air and A/C efficiency.
WARNING: Refer to the applicable warnings and cautions for this system before
performing the following operation. Refer to Heating and Air
Conditioning/Plumbing Warning . Refer to Heating and Air
Conditioning/Plumbing Caution . Failure to follow these instructions may
result in possible serious or fatal injury.
1. Disconnect the battery negative cable.

3. Remove the wheelhouse splash shield. Refer to Body/Exterior/SHIELD, Splash Removal .
2471
Fig. 308: Radiator Hose And Fan Shroud Retainers
4. Remove the lower radiator seal push pins.

5. Remove the lower radiator hose to fan shroud retainers (1).
6. Remove the lower electric cooling fan mounting bolts.
7. Drain the coolant from the radiator. Refer to Cooling Standard Procedur e .
8. Remove the lower radiator hose (2).
10. Remove the grille. Refer to Body/Exterior/GRILLE Removal .

11. Recover the refrigerant from the refrigerant system. Refer to Heating and Air Conditioning/Plumbing
Standard Procedur e .
12. Remove the air filter housing assembly. See Engine/Air Intake System/BODY, Air Cleaner
Removal .
13. Remove the viscous fan, cooling fan and fan shroud as an assembly. Refer to Cooling/Engine/F AN,
Cooling Removal .
14. Remove the upper radiator hose.
2472
15. Remove the nuts (3 and 5) that secure the A/C discharge line (2) and A/C liquid line (4) to the A/C
condenser (1).
16. Disconnect the A/C discharge and liquid lines from the A/C condenser and remove and discard the O
ring seals and gaskets.
17. Install plugs into, or tape over the opened refrigerant line fittings and condenser ports.
Fig. 310: Charge Air Cooler
18. Remove the hoses from the charge air cooler (1).
19. Remove the radiator mounting bolts.
NOTE: Care must be taken not to damage the charge air cooler fins and the fins
of other ancillary cooler components.
20. Remove the radiator, A/C condenser and charge air cooler as an assembly.
21. Remove the charge air cooler to condenser bolts and separate the charge air cooler (1).
Installat ion
INSTALLATION
Fig. 311: Charge Air Cooler
NOTE: 2473
NOTE: When servicing the Air Charge Cooler and/or Turbocharger , the Air Charger
Hose (orange) seal located between the Air Charge Hose and Turbocharger
must be replaced.
1. Install the charge air cooler to the A/C condenser/radiator assembly. Tighten the bolts to 10 N.m (89 in.
lbs.).
NOTE: Care must be taken not to damage the charge air cooler fins and the fins
of other ancillary cooler components.
2. Position the radiator, A/C condenser and charge air cooler into the vehicle as an assembly.
3. Install the radiator mounting bolts. Tighten the bolts to 9 N.m (81 in. lbs.).
4. Install the hoses to the charge air cooler (1). Tighten the clamps to 11 N.m (95 in. lbs.).
5. Remove the tape or plugs from the opened refrigerant line fittings and condenser ports.
6. Lubricate a new rubber Oring seals with clean refrigerant oil and install them and new gaskets onto the
refrigerant line fittings. Use only the specified Oring seals as they are made of a special material for the
R134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
7. Connect the A/C discharge line (2) and the A/C liquid line (4) to the A/C condenser (1). Install the
retaining nuts (3 and 5). Tighten the nuts to 23 N.m (17 ft. lbs.).
8. Install the upper radiator hose.
9. Install the viscous fan, cooling fan and fan shroud as an assembly. Refer to Cooling/Engine/F AN,
Cooling Installation .
10. Install the air filter housing assembly. See Engine/Air Intake System/BODY, Air Cleaner
Installation .
11. Charge the refrigerant system. Refer to Heating and Air Conditioning/Plumbing Standard
Pr ocedur e .
12. Install the grille. Refer to Body/Exterior/GRILLE Installation .
2474
Fig. 313: Radiator Hose And Fan Shroud Retainers

14. Install the lower radiator hose (2).
15. Install the lower electric cooling fan bolts. Tighten the bolts to 6 N.m (53 in. lbs.).
16. Install the lower radiator hose to fan shroud retainers (1).
17. Install the lower radiator seal push pins.
18. Install the wheelhouse splash shield. Refer to Body/Exterior/SHIELD, Splash Installation .
21. Connect the battery negative cable.
22. Start engine and check for leaks.
TURBOCHARGER
Removal
REMOVAL
To remove the turbocharger, see Engine/Manifolds/MANIFOLD, Exhaust Removal.

Installat ion
INSTALLATION
To install the turbocharger, see Engine/Manifolds/MANIFOLD, Exhaust Installation.
VALVE TIMING
STANDARD PROCEDURE
LOCKING ENGINE 90 DEGREES AFTER TDC
2475

2. Remove the upper (4) and lower (2) front covers. See Engine/Valve Timing/COVER(S), Engine
Timing Removal.
Fig. 315: CRANKSHAFT TIMING MARKS
3. Rotate the engine until the 90Â° ATDC marks on the crankshaft timing belt drive sprocket and timing
belt cover are aligned.
2476
4. Remove the engine block plug (1) for the crankshaft locking tool. The crankshaft locking tool is installed
in the high pressure injection pump side of the engine slightly rearward of the engine mount.
5. Install the Crankshaft Locking Tool VM.9992 into the high pressure pump side of the engine block. Make
sure that the outer portion of the tool threads into the block and the bolt threads into the crankshaft. If the
bolt does not thread into the crankshaft, the crankshaft is not at 90Â° ATDC. If necessary, realign the 90Â
° ATDC marks on the crankshaft timing belt drive sprocket and timing belt cover.
Cam shaft Timing Procedure
2477
NOTE: In order to validate camshaft timing, the cylinder head cover and timing belt
should already have been removed.
CAUTION: The camshaft dots time the camshafts to each other. Later in the procedure we
will rotate the camshafts so they are timed to the crankshaft.
1. Line up the camshaft gear dots.
Fig. 319: Camshaft Position Sensor
2. Disconnect the camshaft position sensor harness connector.

3. Remove bolt (1) and the camshaft position sensor (3).
2478
Fig. 320: EXHAUST CAMSHAFT OIL SEAL
4. Remove the exhaust camshaft oil seal (1) to expose the camshaft reluctor.
Fig. 321: Marking CMP Sensor Reluctor Wheel & Exhaust Camshaft
5. Mark the camshaft tone wheel with a paint marker.
2479
CAUTION: Do not rotate the camshaft using the Camshaft Locking Tool VM.9991. The
tone wheel may spin on the camshaft. If the tone wheel is rotated on the
camshaft, the camshaft must be replaced.
6. Rotate the camshafts until the Camshaft Locking Tool VM.9991 can be installed.
7. Install the Camshaft Locking Tool VM.9991.
Fig. 323: Camshaft Marks At 90 Degrees ATDC
8. Verify the camshafts are set correctly at 90Â° ATDC as shown in illustration.
BELT, TIMING
Removal
2480
REMOVAL - TIMING BELT

2. Remove the air cleaner body. See Engine/Air Intake System/BODY, Air Cleaner Removal.
3. Remove the upper and lower timing belt covers. See Engine/Valve Timing/COVER(S), Engine Timing
Removal.
Fig. 325: CRANKSHAFT TIMING MARK
4. Rotate the engine until the crankshaft 90Â° ATDC marks on the crankshaft timing belt drive sprocket and
timing cover are aligned.
2481
5. Remove the engine block plug (1).
6. Install the Crankshaft Locking Tool VM.9992 (1).
2482
7. Disconnect the Camshaft Position Sensor (CMP) harness connector (1).

8. Remove bolt (3) the CMP sensor (2).
Fig. 329: EXHAUST CAMSHAFT OIL SEAL
9. Remove the exhaust camshaft oil seal (1) to expose the camshaft reluctor.
2483
10. Use a paint pen to mark the location of the reluctor wheel (1) on the camshaft (2).
11. Install the Camshaft Locking Tool VM.9991 (1).
2484
Fig. 332: Timing Belt Tensioner Bolt
12. Loosen the timing belt tensioner bolt (1), and remove the timing belt.
Installat ion
INSTALLATION - TIMING BELT
Fig. 333: Fuel Injection Pump Timing Marks
1. Align the high pressure fuel pump sprocket timing mark (2) with the timing mark (3) on the block.
2485
Fig. 334: Timing Belt Tensioner
2. Verify that the bolt (4) is finger tight and tensioner alignment plate (1) is aligned with the boss (2) on the
engine cover.
Fig. 335: Timing Belt Tensioner Adjustment
3. Turn the timing belt tensioner (1) clockwise to unload the tensioner enough for the timing belt to be
installed.
2486
NOTE: DO NOT remove the timing belt from the package until it is going to be
installed. DO NOT expose timing belt to oil, grease or water
contamination. DO NOT crimp belt at a sharp angle. DO NOT clean belt,
pulleys or tensioner with solvent. Check that pulleys and bearings are not
seized or damaged before installing belt.
4. Install the timing belt on the components in the following order.
Fig. 337: Identifying Tensioner Indicator & Tensioner Gage Slot
NOTE: Turning the belt tensioner counter clockwise moves the pointer in a
clockwise direction. Also, if the tensioner bolt is too loose this will cause
the tensioner alignment slot to jump off the alignment boss on timing
cover .
Crankshaft sprocket (1).

2487
High pressure fuel pump (2).
Water pump pulley (3).
Intake camshaft pulley (4).
Timing belt tensioner (5).
5. Adjust timing belt tensioner by lining up the load indicator arrow (1) to the center of the tensioner load
gage (2) as shown in illustration.
Fig. 338: Timing Belt Tensioner Bolt
6. Tighten the timing belt tensioner bolt (1) to 28 N.m (21 ft. lbs.).
7. Verify the tensioner load indicator (1) is still centered in the tensioner load gage (2). If the indicator is not
centered in the gage as shown in illustration, see Engine/Valve Timing/TENSIONER, Engine Timing
Adjustments .
2488
8. Remove the Camshaft Locking Tool VM.9991 (1).
9. Remove the Crankshaft Locking Tool VM.9992 (1).
2489
NOTE: In order to rotate the engine, the Camshaft Locking Tool VM.9991 and the
Crankshaft Locking Tool VM.9992 need to be removed.
10. Rotate engine 2 complete revolutions and then recheck tensioner alignment. Verify that the tension
indicator (1) is centered in the slot on the tensioner gage (2) slot as shown in illustration. Readjust
tensioner alignment is necessary.
11. Verify that the reluctor wheel (1) has not moved on the camshaft. If the witness marks are not aligned, the
reluctor wheel (1) has spun on the camshaft (3) during the assembly process, and the exhaust camshaft
must be replaced.
2490
Fig. 344: Camshaft Oil Seal
12. Use Seal Installer VM.1057 (1) to install the exhaust camshaft seal.
13. Install the Camshaft Position Sensor CMP sensor (2). Tighten bolt (3) to 11 N.m (97 in. lbs.).
14. Connect the (CMP) harness connector (1).
2491
15. Install the engine block plug (1). Tighten the engine block plug to 30 N.m (22 ft. lbs.).
16. Install the upper and lower outer timing belt covers. See Engine/Valve Timing/COVER(S), Engine
Timing Installation.
17. Install the air cleaner body. See Engine/Air Intake System/BODY, Air Cleaner Installation.
COVER(S), ENGINE TIMING

Removal
REMOVAL - INNER TIMING BELT COVER
2492
Fig. 348: Idler Pulley & Bolt
1. Disconnect the negative battery.

3. Remove bolt (1) and the Idler pulley (2).
4. Remove bolts and the inner timing belt cover.

REMOVAL - UPPER AND LOWE R TIMING BELT OUTER COVERS
2493
Fig. 350: Accessory Pulley & Engine Lifting Bracket

2. Remove the fan blade/viscous fan drive assembly from water pump. Refer to Cooling/Engine/DRIVE,
Fan Removal .
3. Remove the front engine lift bracket (2).
4. Remove the accessory drive idler pulley bracket (1).
Fig. 351: UPPER FRONT COVER
5. Remove the upper front cover (2).
2494
Fig. 352: Crankshaft Damper & Bolt
6. Remove the bolts (1) and the crankshaft damper (2).
7. Remove the lower front cover (2).

Installat ion
INSTALLATION - INNER TIMING BELT COVER
2495
1. Install the inner timing belt cover. Tighten the bolts to 8 N.m (71 in. lbs.).
Fig. 355: Idler Pulley & Bolt
2. Install the idler pulley (2). Tighten bolt (1) to 45 N.m (33 ft. lbs.).
INSTALLATION - UPPER AND LOWE R OUTER TIMING BELT COVERS
2496
1. Install the lower timing belt cover (2). Tighten the bolts to 8 N.m (71 in. lbs.).
Fig. 357: Crankshaft Damper & Bolt
2. Install the crankshaft damper (2). Tighten the bolts (1) to 32 N.m (23 in. lbs.).
2497
Fig. 358: UPPER FRONT COVER
3. Install the upper timing belt cover (2). Tighten the bolts to 8 N.m (71 in. lbs.).
Fig. 359: Accessory Pulley & Engine Lifting Bracket
4. Install the accessory drive idler pulley bracket. Tighten the bolts to 45 N.m (33 ft. lbs.).
5. Install the front engine lift bracket (2). Tighten the bolts to 45 N.m (33 ft. lbs.).
6. Install the fan blade/viscous fan drive assembly onto the water pump. Refer to Cooling/Engine/DRIVE,
Fan Installation .
SPROCKET(S), TIMING BELT AND CHAIN

Removal
REMOVAL - CRANKSHAFT SPROCKET
2498

3. Remove bolt (1), and the crankshaft sprocket (2).
REMOVAL - CAMSHAFT SPROCKET
Fig. 361: REMOVE/INSTALL CAMSHAFT SPROCKET BOLT

2. Remove timing belt. See Engine/Valve Timing/BEL T, Timing Removal.
3. Using Locking Tool VM.1055 (1) to hold the intake camshaft sprocket, remove the bolt.
4. Remove the camshaft sprocket.
Installat ion
2499
INSTALLATION - CRANKSHAFT SPROCKET
1. Install the crankshaft sprocket (2). Tighten bolt to 100 N.m (74 ft. lbs.) plus an additional 120 degrees.
INSTALLATION - CAMSHAFT SPROCKET
Fig. 363: REMOVE/INSTALL CAMSHAFT SPROCKET BOLT
1. Install the camshaft sprocket and tighten bolt finger tight.

2. Using locking Tool VM.1055 (1) to hold the camshaft sprocket, tighten the camshaft sprocket (2) bolt to
64 N.m (47 ft. lbs.).
3. Install the timing belt. See Engine/Valve Timing/SPROCKET(S), Timing Belt and Chain
Installation .
2500
TENSIONER, ENGINE TIMING
Removal
REMOVAL - TIMING BELT TENSIONER

Fig. 365: TIMING BELT TENSIONER
3. Remove bolt (4), and timing belt tensioner (3).
Installat ion
INSTALLATION - TIMING BELT TENSIONER
2501
Fig. 366: TIMING BELT TENSIONER
1. Install the timing belt tensioner (3). Do not tighten bolt (4) at this time. Verify that the slot in the
tensioner alignment plate (1) is aligned with the boss (2) in the rear timing belt cover.
NOTE: DO NOT remove the timing belt from the package until it is going to be
installed. DO NOT expose timing belt to oil, grease or water
contamination. DO NOT crimp belt at a sharp angle. DO NOT clean belt,
pulleys or tensioner with solvent. Check that pulleys and bearings are not
seized or damaged before installing belt.

2502
Fig. 368: Timing Belt Routing
Adjustments
ADJ USTMENT
1. With the upper and lower front covers removed and the timing belt installed, loosen timing belt tensioner.
NOTE: Turning the belt tensioner counterclockwise moves the pointer in a

clockwise direction. Also, if the tensioner bolt is too loose this will cause
the tensioner alignment slot to jump off the alignment boss on timing
cover .
2. Adjust timing belt tensioner by lining up the load indicator arrow (1) to the center of the tensioner load
gage (2) as shown in illustration. Tighten the timing belt tensioner bolt to 28 N.m (21 ft. lbs.).
2503
3. Rotate engine 2 complete revolutions and then recheck tensioner alignment. Verify that the tension
indicator (1) is centered in the slot on the tensioner gage (2) slot as shown in illustration. Readjust
tensioner alignment as necessary.
AIR INTAKE SYSTEM

AIR CLEANER
Removal
REMOVAL - AIR CLEANER
Fig. 371: Radiator Fan Electrical Connector
1 ELECTRICAL CONNECTOR
2 UPPER RADIATOR SEAL
1. Disconnect the cooling fan harness connector (1).
2504
Fig. 372: Lock Tabs & Housing Cover
2. Release the four lock tabs (1) and remove the housing cover (2).
Fig. 373: Housing Cover For Filter Element
3. Remove the air filter element.

4. If necessary, clean the inside of the air cleaner housing.
Installat ion
INSTALLATION - AIR CLEANER
2505
Fig. 374: Housing Cover For Filter Element
1. Install new air filter element (1).
Fig. 375: Lock Tabs & Housing Cover
2. Install housing cover (2) and the four snap lock tabs (1) in place.
2506
3. Connect the cooling fan electrical connector (1).
BODY, AIR CLEANER

Removal
REMOVAL
1. Disconnect the cooling fan electrical connector (1).
2507
Fig. 378: Cooling Fan Electrical Connector, Air Cleaner Housing And MAF Sensor
2. Loosen worm clamp and remove the air cleaner outlet tube from air cleaner housing (2).
3. Disconnect the IAT sensor (1).
4. Release the lock tab and disconnect the MAF sensor (3).
Fig. 379: Air Cleaner Assembly
5. To remove the air cleaner assembly, first lift up on air cleaner body to release the three tabs; then
disconnect the inlet tube from housing and remove the air cleaner assembly.
Installat ion
INSTALLATION
2508
Fig. 380: Air Cleaner Assembly
1. Install the air cleaner assembly (1) and connect the inlet tube.
Fig. 381: Cooling Fan Electrical Connector, Air Cleaner Housing And MAF Sensor
2. Connect the MAF sensor (3).

3. Connect the IAT sensor (1).
4. Install the air cleaner outlet tube and tighten the worm clamp (2).
2509
5. Connect the cooling fan electrical connector (1).
2510

01-Engine - 2.8L Diesel

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2010 ENGINE

2.8L Diesel ­ Service Information ­ Wrangler

Fig. 1: 2.8L ENGINE

Never use the following to clean gasket surfaces:

Only use the following for cleaning gasket surfaces:

Solvent or a commercially available gasket remover

STANDARD PROCEDURE ­ COMPRESSION TEST

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

Cylinder compression 10 Bar (44 psi)

1. Disconnect the negative and positive battery cables.

6. Remove the turbocharger air inlet tube at turbo.

Fig. 5: HEATER CORE COOLANT HOSES

Fig. 6: Charge Outlet Hose

23. Remove the generator. Refer to Electrical/Charging/GENERA TOR ­ Removal .

Fig. 9: Refrigerator Lines To Condenser

28. Remove the lower radiator hose at radiator.

Fig. 11: POWER STEERING PUMP PULLEY

29. Remove the power steering pump pulley (1).

Fig. 13: CAMSHAFT POSITION SENSOR HARNESS CONNECTOR

34. Disconnect the fuel injector harness connectors.

Fig. 15: FUEL RAIL

35. Disconnect the turbocharger actuator connector.

40. Disconnect the IAT/BPS harness connector (1).

Fig. 17: Hood Ground Strap

42. Disconnect the glow plug harness connectors.

Fig. 19: STARTER MOUNTING 2.8L DIESEL

45. Remove the starter. Refer to Electrical/Starting/ST ARTER ­ Removal .

46. Disconnect the fuel quantity solenoid.

Fig. 21: FLEX PLATE BOLTS

51. Remove the torque converter to flex plate bolts.

55. Remove the bell housing bolts.

Fig. 23: ENGINE MOUNTS

57. Remove the nut from the left engine mount.

Fig. 25: ENGINE LIFT

1. Install the engine.

Fig. 27: BELL HOUSING BOLTS

5. Install the bell housing bolts:

Fig. 29: Fuel Pump Return Line

16. Install the starter. Refer to Electrical/Starting/ST ARTER ­ Installation .

Fig. 31: Glow Plugs

17. Connect the brake booster vacuum hose.

Fig. 33: IAT/BPS SENSOR

21. Connect the IAT/BPS harness connector (1).

22. Connect the EGR airflow control valve harness connector.

Fig. 35: INJECTOR CONNECTOR

27. Connect the fuel injector harness connectors.

Fig. 37: Power Steering Pump

29. Connect the EGR vacuum solenoid harness connector.

Fig. 39: Removing/Installing Lower Radiator Hose

33. Install the lower radiator hose at radiator.

Fig. 41: A/C COMPRESSOR

38. Install the generator. Refer to Electrical/Charging/GENERA TOR ­ Installation .

Fig. 43: Charge Outlet Hose

Fig. 45: CAC Turbo Outlet

CYLINDER HEAD GASKET SELECTION

Fig. 47: REMOVER, SEAL ­ VM.1058

Fig. 48: BALANCE SHAFT LOCK PIN ­ VM.10012

Fig. 50: FRONT AND REAR SEAL TOOL ­ VM.9990

Fig. 51: ADAPTER, COMPRESSION TEST ­ VM.1072A

2.8L Diesel Service Information Wrangler

STANDARD PROCEDURE COMPRESSION TEST

23. Remove the generator. Refer to Electrical/Charging/GENERA TOR Removal .

45. Remove the starter. Refer to Electrical/Starting/ST ARTER Removal .

16. Install the starter. Refer to Electrical/Starting/ST ARTER Installation .

38. Install the generator. Refer to Electrical/Charging/GENERA TOR Installation .

Fig. 47: REMOVER, SEAL VM.1058

Fig. 48: BALANCE SHAFT LOCK PIN VM.10012

Fig. 50: FRONT AND REAR SEAL TOOL VM.9990

Fig. 51: ADAPTER, COMPRESSION TEST VM.1072A

Fig. 53: INSTALLER, SEAL VM.1057

Fig. 54: CAMSHAFT TIMING TOOL VM.9991

Fig. 56: CRANKSHAFT SEAL INSTALLER VM.9993

Fig. 58: Valve Spring Adapter MD998772A15

Fig. 63: MD998772A15 ADAPTOR

Fig. 103: Fuel Return LinesTop