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Diesel Engine

NOTE:

Use coolant on the seals of the thermostat housing so the seals wont become damaged and to help aid in installation.

Fig 1: Identifying Thermostat Housing & Accessory Carrier Bracket
GC0137782Courtesy of CHRYSLER GROUP, LLC
  1. Install the thermostat housing (2) into the accessory carrier bracket (1) by using hand pressure and twisting motion to seat the housing into place.
    Fig 2: Identifying Thermostat Heater Connector & Upper Thermostat Housing Bolt
    GC0137798Courtesy of CHRYSLER GROUP, LLC
  2. Install the two thermostat housing mounting bolts (2). Tighten the bolts to 9 N.m (80 in. lbs.).
  3. Connect the thermostat heater connector (1).
    Fig 3: EGR Air Flow Control Valve & Bolts
    GC0137803Courtesy of CHRYSLER GROUP, LLC
  4. Install the EGR (3) and the inlet nozzle (1). Install two bolts (2) to support nozzle and EGR in place. Do not tighten.
  5. Raise vehicle.
  6. Install all mounting screws (2) for the EGR throttle control housing and the inlet nozzle, to the mixing tank. Tighten bolts (2) to 9 N.m (80 in. lbs.).
  7. Install the brake booster check valve vacuum line at the pump.
    Fig 4: Pressure Line At Pump
    GC0137797Courtesy of CHRYSLER GROUP, LLC
  8. Install the water/power steering pump assembly. Refer to PUMP, WATER, INSTALLATION .
    Fig 5: Identifying Main Drive Belt
    GC0137780Courtesy of CHRYSLER GROUP, LLC
  9. Install the main drive belt (3).
    Fig 6: Identifying Charge Air Temperature Sensor Connectors
    GC0137801Courtesy of CHRYSLER GROUP, LLC
  10. Lower vehicle.
  11. Install lower thermostat housing hose clamp onto combination water/power steering pump.
  12. Connect the EGR throttle control and charge air temperature sensor connectors (1).
    Fig 7: Vacuum Tube Bolt
    GC0137800Courtesy of CHRYSLER GROUP, LLC
  13. Install the upper brake booster vacuum line bracket bolt (1).
    Fig 8: Identifying Front Upper & Lower Air Charge Hose
    GC0137799Courtesy of CHRYSLER GROUP, LLC
  14. Install the front lower air charge hose (2). Tighten hose clamps to 2 N.m (18 in. lbs.).
  15. Install the front upper air charge hose (1). Tighten hose clamps to 2 N.m (18 in. lbs.).
  16. Install the fan module assembly. Refer to FAN, COOLING, INSTALLATION .
  17. Add coolant. Refer to STANDARD PROCEDURE .
  18. Add power steering fluid. Refer to STANDARD PROCEDURE .
  19. Connect the negative battery cable.
  20. Run engine to operating temperature and check for leaks.
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