Position Engine On Engine Stand

REMOVAL 

Courtesy of CHRYSLER GROUP, LLC

1. Remove the bolt and remove the compressor wiring harness mounting bracket (1).

   Courtesy of CHRYSLER GROUP, LLC

2. Install the (special tool #2055100090, Service belt tensioner bracket) (1a) and securely tighten the bolts (1b).

   Courtesy of CHRYSLER GROUP, LLC

3. Using a suitable breaker bar (1a), load the tool (1b) to compress the spring of the stretcher and release the tension of the auxiliary belt.

   Courtesy of CHRYSLER GROUP, LLC

4. Remove the bolts (1a) and disconnect the air outlet pipe from the left turbocharger (1b).

   Courtesy of CHRYSLER GROUP, LLC

5. Loosen the clamp (1a), disconnect the turbocharger air bypass sleeve from the solenoid valve to the left pipe (1b) and remove the left turbocharger air outlet pipe (1c) complete with seal.

   Courtesy of CHRYSLER GROUP, LLC

6. Disconnect the air conditioning compressor wire harness connection (1).

   Courtesy of CHRYSLER GROUP, LLC

7. Remove the bolt (1) securing the line from the A/C compressor to the condenser, on the compressor side.
8. Remove the bolt (2) securing the line from the compressor to the expansion valve connector, compressor side.

   Courtesy of CHRYSLER GROUP, LLC

9. Remove the line from the compressor to A/C condenser and the line from compressor to expansion valve connector (1).

   Courtesy of CHRYSLER GROUP, LLC

10. Remove the front bolt (1) securing the A/C compressor to the engine.

    Courtesy of CHRYSLER GROUP, LLC

11. Remove the lower bolt (1) securing the A/C compressor to the engine.

    Courtesy of CHRYSLER GROUP, LLC

12. Remove the rear bolt (1a) securing the A/C compressor to the engine and release the compressor line support bracket (1b).

    Courtesy of CHRYSLER GROUP, LLC

13. Remove the A/C compressor (1).

    Courtesy of CHRYSLER GROUP, LLC

14. Remove the A/C line assembly (1).

    Courtesy of CHRYSLER GROUP, LLC

15. Disconnect the generator wire harness connector (1).
16. Remove the cover (2a), then remove the nut (2b) and disconnect the wiring.

    Courtesy of CHRYSLER GROUP, LLC

17. Remove the lower generator mounting bolts (1).

    Courtesy of CHRYSLER GROUP, LLC

18. Remove the upper mounting bolts (1a) and remove the generator (1b).

    Courtesy of CHRYSLER GROUP, LLC

19. Remove the bolts (1a) and disconnect the air outlet pipe from the right turbocharger (1b).

    Courtesy of CHRYSLER GROUP, LLC

20. Loosen the clamp (1a), disconnect the turbocharger air bypass sleeve from the solenoid valve to the right pipe (1b) and remove the right turbocharger air outlet pipe (1c) complete with seal.

    Courtesy of CHRYSLER GROUP, LLC

21. Loosen the clamp (1a) and disconnect the radiator coolant inlet multi-way pipe (1b), complete with hose between multi-way connector and thermostat.

    Courtesy of CHRYSLER GROUP, LLC

22. Remove the generator wiring from the retainers (1).
23. Remove the bolts (2) securing the generator wiring support bracket.

    Courtesy of CHRYSLER GROUP, LLC

24. Release the generator wiring from the retainers (1) and position it aside.

    Courtesy of CHRYSLER GROUP, LLC

25. Remove the lower bolts (1) securing the turbocharger air-water heat exchanger support.

    Courtesy of CHRYSLER GROUP, LLC

26. Remove the upper bolts (1a) and remove the turbocharger air-water heat exchanger support (1b).

    Courtesy of CHRYSLER GROUP, LLC

27. Release and remove the accessory drive belt (1).

    Courtesy of CHRYSLER GROUP, LLC

28. Working through the pulley holes, remove the bolts (1a) and remove the water pump (1b).
29. Replace the O-ring (2) on the water pump.

    Courtesy of CHRYSLER GROUP, LLC

30. Install the (special tool #2024200090, Damper, Rotating Tool) (1) on the crankshaft service pulley.

    Courtesy of CHRYSLER GROUP, LLC

31. Remove the bolts (1a) and remove the damper on the crankshaft (1b), complete with washer (1c).

    Courtesy of CHRYSLER GROUP, LLC

32. Remove the engine coolant outlet pipe connector (1) from left turbocharger, coolant pump inlet side.
33. Remove the bolt (2) securing the pipe mounting bracket and position the pipe aside.

    Courtesy of CHRYSLER GROUP, LLC

34. Install the four (special tool #2024300090, Brackets, Engine Lifting) (1) on the left and right cylinder head.
35. Support the engine with a suitable lift.

    Courtesy of CHRYSLER GROUP, LLC

36. Install the (special tool #2032100090, Adapter, Engine Stand) (1) on the crankcase.

37. Courtesy of CHRYSLER GROUP, LLC

38. Lift the engine (1a) and place it on the overhaul stand (1b).
39. Remove the tools used for lifting the engine.

INSTALLATION 

1. Support the engine using the mounting tools and a suitable hydraulic hoist.

   Courtesy of CHRYSLER GROUP, LLC

2. Remove the engine (1a) from the overhaul stand (1b) and place it on a suitable platform.
3. Remove the tools used for lifting the engine.

   Courtesy of CHRYSLER GROUP, LLC

4. Remove the adaptor bracket (1).

   Courtesy of CHRYSLER GROUP, LLC

5. Install the engine coolant outlet pipe (1a) from left turbocharger and securely tighten the bolt (1b) of the intermediate pipe support bracket.
6. Tighten the engine coolant outlet pipe connector (2) from left turbocharger, coolant pump inlet side, to the proper torque specification. Refer to TORQUE SPECIFICATIONS .

   Courtesy of CHRYSLER GROUP, LLC

7. Install the damper on the crankshaft (1a), complete with washer (1b), install the (special tool #2024200090, Damper, Rotating Tool) and tighten the bolts (1c) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .

   Courtesy of CHRYSLER GROUP, LLC

8. Install the water pump (1a), using a new O-ring, and tighten the bolts (1b) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .

   Courtesy of CHRYSLER GROUP, LLC

9. Install the accessory drive belt (1) so that it is positioned as shown in illustration.
10. Visually check that all the belt grooves are inserted in those of the water pump pulley and those of the damper on the crankshaft.
    • A - Smooth Outer Side
    • B - Ribbed Inner Side

    Courtesy of CHRYSLER GROUP, LLC

11. Install the turbocharger air-water heat exchanger support (1a), install the belt onto the fixed and mobile stretchers correctly and tighten the upper bolts (1b) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .

    Courtesy of CHRYSLER GROUP, LLC

12. Tighten the lower bolts (1) securing the turbocharger air-water heat exchanger support to the proper torque specification. Refer to TORQUE SPECIFICATIONS .

    Courtesy of CHRYSLER GROUP, LLC

13. Install the generator wiring and engage it in the retainers (1).

    Courtesy of CHRYSLER GROUP, LLC

14. Securely tighten the bolts (1) of the alternator wiring mounting brackets.
15. Secure the alternator wiring in the retainers (2).

    Courtesy of CHRYSLER GROUP, LLC

16. Connect the radiator coolant inlet multi-way pipe (1a), complete with hose between multi-way connector and thermostat and securely tighten the clamp (1b).

    Courtesy of CHRYSLER GROUP, LLC

17. Install the right turbocharger air outlet pipe (1a), complete with seal, connect the turbocharger air bypass sleeve from the solenoid valve to the right pipe (1b) and securely tighten the clamp (1c).

    Courtesy of CHRYSLER GROUP, LLC

18. Connect the air outlet pipe from the right turbocharger (1a) and securely tighten the bolts (1b).

    Courtesy of CHRYSLER GROUP, LLC

19. Install the alternator fit the belt correctly onto the pulley (1).
20. Visually check that all the belt grooves are inserted in those of the pulley.

    Courtesy of CHRYSLER GROUP, LLC

21. Tighten the alternator upper bolt (1) to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .

    Courtesy of CHRYSLER GROUP, LLC

22. Tighten the alternator lower bolts (1) to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .

    Courtesy of CHRYSLER GROUP, LLC

23. Connect the wiring and securely tighten the nut (1a), then install the cover (1b).
24. Connect the wire harness connection (2) for the alternator.

    Courtesy of CHRYSLER GROUP, LLC

25. Replace the O-rings.
    NOTE:

    Only use seal washers with an elastomeric part in HNBR, resistant to refrigerant R1234YF. The use of seal washers with another elastomeric material may increase the risk of serious leaks of refrigerant from the air conditioning system.

26. Install the A/C line assembly (1).
27. Install the compressor and position the belt correctly onto the pulley.
28. Visually check that all the belt grooves are inserted in those of the pulley.

    Courtesy of CHRYSLER GROUP, LLC

29. Tighten the rear bolt (1a) securing the A/C compressor to the engine to the proper and engage the compressor pipe mounting bracket (1b). Refer to TECHNICAL SPECIFICATIONS .

    Courtesy of CHRYSLER GROUP, LLC

30. Tighten the lower bolt (1) securing the A/C compressor to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .

    Courtesy of CHRYSLER GROUP, LLC

31. Tighten the front bolt (1) securing the A/C compressor to the engine to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .

    Courtesy of CHRYSLER GROUP, LLC

32. Tighten the bolt (1) securing the pipe from the A/C compressor to the condenser, on the compressor side, to the proper torque specification. Refer to TECHNICAL SPECIFICATIONS .
33. Tighten the bolt (2) securing the pipe from the compressor to the expansion valve connector, compressor side, to the proper. Refer to TECHNICAL SPECIFICATIONS .

    Courtesy of CHRYSLER GROUP, LLC

34. Connect the wire harness connection (1) for the air conditioning compressor.

    Courtesy of CHRYSLER GROUP, LLC

35. Install the left turbocharger air outlet pipe (1a), complete with seal, connect the turbocharger air bypass sleeve from the solenoid valve to the left pipe (1b) and securely tighten the clamp (1c).

    Courtesy of CHRYSLER GROUP, LLC

36. Connect the air outlet pipe from the left turbocharger (1a) and securely tighten the bolts (1b).

    Courtesy of CHRYSLER GROUP, LLC

37. Using the retainer (1a), release the tool (1b) to decompress the spring of the mobile stretcher and restore the tension of the auxiliary belt.

    Courtesy of CHRYSLER GROUP, LLC

38. Remove the bolts (1a) and remove the tool (1b).

    Courtesy of CHRYSLER GROUP, LLC

39. Install the compressor wiring harness mounting bracket and securely tighten the bolt (1).