TORQUE
2.8L DIESEL TORQUE SPECIFICATIONS
DESCRIPTION / N·m / Ft. Lbs. / In. Lbs.Oil Pump Bolts / 10.8 / 8 / 96
Vacuum Pump Bolts / 10.8 / 8 / 96
Vacuum Pump Pipe to Block / 56.9 / 42 / —
Crankshaft Gear Bolts / 10.8 / 8 / 96
Crankshaft Position Sensor Bolts / 10.8 / 8 / 96
Flywheel Bolts - 2.8L, Refer to the Service Procedure
Flex Plate Bolts - 2.8L, Refer to the Service Procedure
Cylinder Head Bolts - Refer to the Service Procedure
Reluctor Wheel Bolts / 14.6 / 11 / 130
Rear Main Bearing Support Bolts / 27.5 / 21 / 240
Oil Cooler to Engine Block Bolt / 47.1 / 35 / —
Engine Block Plug In Front Of Oil Cooler / 58.8 / 43 / —
Oil Cooler Mounting Stud / 50 / 37 / —
Oil Level Indicator to Cylinder Head Cover / 10.8 / — / 96
Oil Level Indicator Tube to Pan / 10.8 / — / 96
Water Pump Housing Nuts / 24.4 / 18 / 212
Connecting Rod Bolts - Refer to the Service Procedure
Balance Shaft Bolts / 32.4 / 24 / —
Oil Jet Bolts / 10.8 / 8 / 96
Oil Pump Pick-up Tube / 32.4 / 24 / —
Oil Pan Bolts / 11.8 / 8 / 96
Structural Support to Engine and Transmission Bolts / 45.1 / 33 / —
Crankshaft Hub Bolt / 275 / 203 / —
Crankshaft Pulley Bolts / 32.4 / 24 / —
Front Engine Cover Bolts / 6 / — / 53
Transmission to Engine Bolts / 83.4 / 62 / —
Cylinder Head Cover / Intake Manifold Bolts / 24.5 / 18 / —
Camshaft Timing Access Bolts / 24.5 / 18 / —
Camshaft Access Plugs / 80 / 59 / —
Oil Separator Bolts / 10.8 / 8 / 96
Camshaft Position Sensor Bolt / 10.8 / 8 / 96
Boost Pressure / Intake Air Temp. Sensor Bolts / 5.4 / — / 48
Glow Plug / 12.5 / — / 110
Accessory Drive Bracket Bolts / 45.1 / 33 / —
Accessory Drive Belt Idler Pulley Bolt / 53 / 39 / —
Vacuum Line Fitting Bolt / 56.9 / 42 / —
Fuel Pump Nuts / 27.5 / 21 / —
Fuel Line Fittings at Pump / 27.5 / 21 / —
Fuel Rail Retaining Bolts / 24.5 / 18 / 217
Inner Timing Belt Cover Bolts
8mm / 10.8 / 8 / 96
10mm / 45.1 / 33 / —
Outer Timing Belt Cover Bolts
3mm / 6 / — / 54
8mm / 10.8 / 8 / 96
Engine Mount Bracket to Cylinder Head Bolts / 45.1 / 33 / —
Structural Support to Engine and Transmission Bolts / 45.1 / 33 / —
Intake Inlet Tube Bolts / 10.1 / 8 / 89
Camshaft Sprocket Bolts / 108 / 80 / —
Camshaft Timing Access Bolts / 24.5 / 18 / 212
Timing Belt Idler Pulley Bolt / 47.1 / 35 / —
Timing Belt Tensioner Bolt / 29.4 / 22 / —
Fuel Injection Pump Gear Nut / 88.3 / 65 / —
Fuel Injection Pump Retaining Nuts / 24.4 / 18 / 212
Engine Lift Hook Bolts / 45.1 / 33 / —
Thermostat Housing Bolts / 24.5 / 18 / —
Turbocharger Oil Supply Line Fitting / 24.5 / 18 / 217
Turbocharger Oil Return Line Bolts / 10.8 / — / 96
Exhaust Manifold Nuts / 36 / 26.5 / —
Exhaust Manifold Heat Shield / 24.5 / 18 / 217
Exhaust Manifold Heatshield Bolts / 27.5 / 21 / —
EGR Valve Bolts / 24.5 / 18 / —
EGR Air Control Valve to Cylinder Head Cover / 10.8 / — / 96
Coolant Pipe to EGR Valve Bolts / 24.5 / 18 / —
Turbocharger Downpipe Nuts / 32.4 / 24 / —
Turbocharger Support Bracket Bolts / 24.5 / 18 / —
Vibration Damper to Crankshaft Hub Bolts / 27.5 / 21 / —
Crankshaft Support Bolts / 44.1 / 33 / —
Turbocharger to Exhaust Manifold Nuts / 32.4 / 24 / —
Portions of materials contained herein are sourced from Chrysler Corporation.
Copyright 2007 - 2013 Service Repair Solutions, Inc.
INSTALLATION - CYLINDER HEAD
CAUTION:Piston protrusion must be measured to determine cylinder head gasket thickness if one or more cylinder liners have been replaced ( Refer to 9 - ENGINE/CYLINDER HEAD - STANDARD PROCEDURE) .
NOTE:If cylinder liner(s) have not been removed, the same thickness head gasket that was removed can be used.
- Clean and inspect gasket mating surfaces.
- Position correct head gasket on engine block.
- Place cylinder head on engine block.
CAUTION:New cylinder head bolts must be used. Do Not lubricate new cylinder head bolts. They already are coated with an anti scuff treatment.
- Tighten cylinder head bolts following procedure below.
Cylinder Head Bolt Torquing Procedure
- Tighten all cylinder head bolts to 30 N.m (22 ft.lbs.) starting from the center bolts, following the cylinder head scheme and the following sequence: 3-2-1-10-9-8-7-6-5-4-11-12-13-14-15-16-17-18.( CYLINDER HEAD TIGHTENING).
- Without loosening any bolts, starting from the center bolts, tighten each bolt an additional 75° in the following sequence: 10-9-8-7-6-5-4-3-2-1.( CYLINDER HEAD TIGHTENING).
- Tighten the lateral cylinder head bolts an additional 50° in the following sequence: 11-12-13-14-15-16-17-18.( CYLINDER HEAD TIGHTENING).
- Finally tighten all bolts an additional 75° in the following sequence: 10-9-8-7-6-5-4-3-2-1-11-12-13-14-15-16-17-18.( CYLINDER HEAD TIGHTENING).
- Slide exhaust manifold and turbocharger on exhaust manifold studs ( THERMOSTAT HOUSING).
- Install exhaust manifold retaining nuts. Tighten the nuts to 36 N·m. ( 27 ft. lbs) in a cross sequence beginning in the middle and working outward, then perform the tightening sequence to the exhaust manifold nuts again.
- Install exhaust manifold heat shield. Torque bolts to 24.5N·m.(217 in. lbs).
- Install turbocharger outlet to charge air cooler pipe.
- Install upper radiator hose.
- Connect glow plug and coolant temperature sensor electrical connectors.
- Install new cylinder head cover/intake manifold gasket.
- Install rocker arm and lifter assemblies. Be sure to put rocker arm and lifter assemblies in same location as removed.
CAUTION:Care must be taken not to knock the rocker arms off of the valves when installing the cylinder head cover/intake manifold.
- Install cylinder head cover/intake manifold(Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION) .
- Install timing belt inner cover ( Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION) .
NOTE:Make sure the crankshaft is rotated to the 90 degree ATDC, or the 3 O'clock position and special tool VM1089 is installed in the 90 degree ATDC access hole.( Refer to 9 - ENGINE/VALVE TIMING - STANDARD PROCEDURE).
- Install both camshaft gears and tighten bolts finger tight.
- Install timing belt ( Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) .
- Using VM.1085, torque cam gear retaining bolts to 108 N·m.( VM.1085 CAMSHAFT LOCKING TOOL).
- Install timing belt outer cover ( Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION) .
- Remove both camshaft locking pins at this time( Refer to 9 - ENGINE/VALVE TIMING - STANDARD PROCEDURE) .
- Install fuel injectors ( Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - INSTALLATION).
- Install brake booster line bracket to intake manifold.
- Install oil level indicator tube to intake manifold.
- Connect fuel pump high pressure line to fuel rail.
- Install fuel injector pressure lines.
- Connect fuel return hose to fuel injectors.
- Connect engine coolant hoses to thermostat housing.
- Raise vehicle.
- Reconnect exhaust system bracket at transmission crossmember.
- Connect exhaust stabilizer bracket to lower exhaust manifold ( THERMOSTAT HOUSING).
- Install turbocharger oil supply line to turbocharger.
- Lower vehicle.
- Install turbocharger heat shield.
- Install exhaust manifold heat shield.
- Install air cleaner housing.
- Install main engine wiring harness and connect all ancillary electrical components.
- Install viscous heater.
- Install vibration damper ( Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION).
- Install generator ( Refer to 8 - ELECTRICAL/CHARGING/GENERATOR - INSTALLATION) .
- Install cooling fan support ( Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION) .
- Install front engine lift bracket.
- Install power steering pump pulley.
- Install accessory drive belt tensioner and both idler pulleys. Idler pulley retaining bolts are L. H. Thread.
- Install accessory drive belt ( Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION) .
- Install cooling fan and fan drive viscous clutch assembly ( Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION) .
- Install upper radiator core support.
- Refill cooling system ( Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE) .
- Remove special tool VM 1089 from the 90 degree ATDC access hole.
- Install engine cover and bracket ( Refer to 9 - ENGINE COVER - INSTALLATION) .
- Connect negative battery cable.
- Start engine and allow to warm. Turn engine off and inspect for leaks ( Refer to 14 - FUEL SYSTEM - WARNING) .
Portions of materials contained herein are sourced from Chrysler Corporation.
Copyright 2007 - 2013 Service Repair Solutions, Inc.