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Diesel Engine

Fig 1: Identifying Air Inlet Tube
GC0138466Courtesy of CHRYSLER GROUP, LLC
  1. Disconnect the negative battery cable.
  2. Remove the air intake duct (2).
  3. Siphon the power steering fluid from the reservoir.
  4. Remove the fan module assembly. Refer to FAN, COOLING, REMOVAL .
    Fig 2: Identifying Front Upper & Lower Air Charge Hose
    GC0137799Courtesy of CHRYSLER GROUP, LLC
  5. Remove the front upper air charge hose (1).
  6. Remove the front lower air charge hose (2) to the EGR throttle control housing.
    Fig 3: Vacuum Tube Bolt
    GC0137800Courtesy of CHRYSLER GROUP, LLC
  7. Remove the brake booster vacuum line support bracket (1).
    Fig 4: Identifying Charge Air Temperature Sensor Connectors
    GC0137801Courtesy of CHRYSLER GROUP, LLC
  8. Disconnect the wire harness connector to the EGR air flow control valve and charge air temperature sensor (1).
  9. Loosen the lower hose clamp from the thermostat housing to the combination water/power steering pump.
    Fig 5: Identifying Main Drive Belt
    GC0137780Courtesy of CHRYSLER GROUP, LLC
  10. Raise the vehicle.
  11. Remove main drive belt (3). Refer to BELT, SERPENTINE, REMOVAL .
    Fig 6: Pressure Line At Pump
    GC0137797Courtesy of CHRYSLER GROUP, LLC
  12. Remove the water/power steering pump assembly. Refer to PUMP, WATER, REMOVAL .
    Fig 7: Vacuum Hose At Vacuum Pump
    GC0137802Courtesy of CHRYSLER GROUP, LLC
  13. Remove the brake booster vacuum line check valve (1) from the vacuum pump.
    Fig 8: EGR Air Flow Control Valve & Bolts
    GC0137803Courtesy of CHRYSLER GROUP, LLC
  14. Remove the four mounting screws (2) from the EGR throttle control (3) to the mixing tank.
  15. Position the inlet nozzle (1) aside, to be removed from the top side of vehicle.
  16. Remove the EGR throttle control assembly (3).
    NOTE:

    The thermostat must be replaced with the housing. Trying to remove the thermostat from the housing will damage the housing and the thermostat.

    Fig 9: Identifying Thermostat Heater Connector & Upper Thermostat Housing Bolt
    GC0137798Courtesy of CHRYSLER GROUP, LLC
  17. Remove the lower thermostat housing mounting bolt (2).
  18. Lower vehicle.
  19. Remove the intake nozzle.
  20. Disconnect the thermostat heater connector (1).
  21. Remove the upper thermostat housing bolt (2).
  22. Remove the thermostat housing by moving the housing in a side to side motion.
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