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.

  1. Clean and inspect gasket mating surfaces.
  2. Position correct head gasket on engine block.
  3. 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.

  1. 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).
  1. Slide exhaust manifold and turbocharger on exhaust manifold studs ( THERMOSTAT HOUSING).
  2. 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.
  3. Install exhaust manifold heat shield. Torque bolts to 24.5N·m.(217 in. lbs).
  4. Install turbocharger outlet to charge air cooler pipe.
  5. Install upper radiator hose.
  6. Connect glow plug and coolant temperature sensor electrical connectors.
  7. Install new cylinder head cover/intake manifold gasket.
  8. 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.

  1. Install cylinder head cover/intake manifold(Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION) .
  2. 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).

  1. Install both camshaft gears and tighten bolts finger tight.
  2. Install timing belt ( Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION) .
  3. Using VM.1085, torque cam gear retaining bolts to 108 N·m.( VM.1085 CAMSHAFT LOCKING TOOL).
  4. Install timing belt outer cover ( Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION) .
  5. Remove both camshaft locking pins at this time( Refer to 9 - ENGINE/VALVE TIMING - STANDARD PROCEDURE) .
  6. Install fuel injectors ( Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - INSTALLATION).
  7. Install brake booster line bracket to intake manifold.
  8. Install oil level indicator tube to intake manifold.
  9. Connect fuel pump high pressure line to fuel rail.
  10. Install fuel injector pressure lines.
  11. Connect fuel return hose to fuel injectors.
  12. Connect engine coolant hoses to thermostat housing.
  13. Raise vehicle.
  14. Reconnect exhaust system bracket at transmission crossmember.
  15. Connect exhaust stabilizer bracket to lower exhaust manifold ( THERMOSTAT HOUSING).
  16. Install turbocharger oil supply line to turbocharger.
  17. Lower vehicle.
  18. Install turbocharger heat shield.
  19. Install exhaust manifold heat shield.
  20. Install air cleaner housing.
  21. Install main engine wiring harness and connect all ancillary electrical components.
  22. Install viscous heater.
  23. Install vibration damper ( Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION).
  24. Install generator ( Refer to 8 - ELECTRICAL/CHARGING/GENERATOR - INSTALLATION) .
  25. Install cooling fan support ( Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION) .
  26. Install front engine lift bracket.
  27. Install power steering pump pulley.
  28. Install accessory drive belt tensioner and both idler pulleys. Idler pulley retaining bolts are L. H. Thread.
  29. Install accessory drive belt ( Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION) .
  30. Install cooling fan and fan drive viscous clutch assembly ( Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION) .
  31. Install upper radiator core support.
  32. Refill cooling system ( Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE) .
  33. Remove special tool VM 1089 from the 90 degree ATDC access hole.
  34. Install engine cover and bracket ( Refer to 9 - ENGINE COVER - INSTALLATION) .
  35. Connect negative battery cable.
  36. 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.