2012 Jeep Wrangler JK Factory Service Manual 09 - Engine, 2.8L Diesel

09 - Engine, 2.8L Diesel

DESCRIPTION

DESCRIPTION


The 2.8L (2777cc) four-cylinder “common rail” direct injection engine is an in-line overhead valve design. The engine utilize a cast iron cylinder block. The engine has a one piece aluminum cylinder head with four valves per cylinder and dual overhead cam shafts. The 2.8L is turbocharged, intercooled and also equipped with a EGR cooler.

The identification stamp for the 2.8L is located on the left side of the engine block, above the starter. The engine code label is located on the front timing cover and is the same as the engine I.D. and serial number. There is also a fuel system label on the front timing cover used for fuel system identification during PCM programming.

DUST COVERS AND CAPS

DUST COVERS AND CAPS

Special Tools: Click to display a list of tools used in this procedure

Due to the high amounts of failures caused by dust, dirt, moisture and other foreign debris being introduced to the engine during service. Covers or caps are needed to reduce the possible damage that can be caused or created.


Covers over openings will reduce any possibilities for foreign materials to enter the engine systems. Using miller tool Set, Universal Protective Cap 10368 , Select the appropriated cover needed to the procedure.

ENGINE GASKET SURFACE PREPARATION

ENGINE GASKET SURFACE PREPARATION


To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets.

Never use the following to clean gasket surfaces:



NOTE:

Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.

Only use the following for cleaning gasket surfaces:

COMPRESSION TEST

COMPRESSION TEST

Special Tools: Click to display a list of tools used in this procedure

  1. Warm up engine to operating temperature (approximately 80 °C, 176 °F).

  2.  
  3. Shut off the engine.

  4.  
  5. Disable the low pressure fuel pump.

  6.  
  7. Remove the fuel injectors (Refer to 14 - Fuel System/Fuel Injection/INJECTOR(S) , Fuel - Removal).

  8.  
  9. Crank engine several times with the starter to eliminate combustion residues in the cylinders.

  10.  
  11. Insert the Adapter, Compression Test VM.10010 into injector hole of cylinder to be tested. Install injector retainer bolts and tighten.

  12.  
  13. Test compression pressure by cranking engine with starter for at least 8 revolutions.

    Cylinder compression Difference Between Cylinders

    10 Bar (145 psi)


  14.  
  15. Carry out test procedure at the remaining cylinders in the same way.

  16.  
  17. Remove the Adapter, Compression Test VM.10010 from cylinder head.

  18.  
  19. Install injectors (Refer to 14 - Fuel System/Fuel Injection/INJECTOR(S) , Fuel - Installation).

  20.  

SPECIFICATIONS

SPECIFICATIONS


2.8L Engine Specifications

Engine

2.8L JK/KK

Engine Type

2.8L — 16 Valves

Displacement

2777 cc

Bore

94.00

Stroke

100.05

Power (VGT) JK - KK

147 kW (200CV) @ 3600 RPM

Torque (ATX) JK - KK

460 N·m @ 1600 - 2600 RPM

Torque (MTX) JK - KK

410 N·m @ 2000 - 3200 RPM

Cylinders

4 In line

Injection Order

1–3–4–2

Compression Ratio

16.5:1

Vacuum at idle

600 mm/HG (27.5 In/HG) @ 800 RPM

Idle Speed (ATX) JK

760 +/- 50 RPM

Idle Speed (ATX) KK

730 +/- 50 RPM

Idle Speed (MTX) JK - KK

875 +/- 50 RPM

Maximum RPM in Gear

6600 RPM

Maximum RPM in neutral

ATX 3000 MTX 3000

Belt tension

Automatic Belt Tensioner

Thermostat opening

90°C +/- 2°C

Generator Rating

Denso 12V-180A; JK MTX 12V-220A

Emissions Level

EU5

Block configuration/Material

Open/Cast Iron

Cylinder Head

Dual Overhead Cam

Timing System

Belt

Fuel System

CP1H HP pump, 1800 bar, Piezo Injectors CRI 13.2

Fuel Supply

Electric Fuel Pump In the Fuel Tank

Electronic Control Unit

EDC 17

Timing System

Belt Driven DOHC Overhead Camshaft

Air Intake

Dry Filter With turbocharger and Charge Air Cooler

Fuel System

Direct Fuel Injection Common Rail System

Emission Devices

Cooled EGR (electric DC motor)

Electric Intake Throttle

Fast Metallic Glow plugs

Combustion Cycle

4 Stroke

Cylinder Compression Difference Between Cylinders

10 bar (145 psi)

Cooling System

Water Cooling

Turbocharger

Single VGT with REA

Intake Ports

Aluminum heads with traditional dual side intake and exhaust ports. One intake port is helical and the other has a directed entry.

Crankshaft

8 Counterweights with an incorporated balance shaft gear.

Camshafts

2 overhead camshafts with axial front bearings and identical camshaft caps, finger followers, and hydraulic lifters.

Intake AND Exhaust Valves

Flat with fire deck face.

Intake Manifold

Plastic, with integrated swirl control flap and actuator

Lubrication

Pressure Lubricated By Rotary Pump

Minimum Oil Pressure (warm)

0.7 BAR at idle / 2.5 BAR at 3800 rpm

Engine Rotation

Clockwise Viewed From Front Cover

Engine Oil Capacity With Filter

6.6L (7 Quarts)


2.8L Engine Specifications

Cylinder Head

Cylinder head height

135.5 mm (5.334 in.)

Cylinder head flatness deformation tolerance

0.075 mm (0.003 in.)

Cylinder Head Gasket Thickness

0 Hole

1.10 mm ( 0.043 in)

1 Hole

1.20 mm (0.047 in)

2 Holes

1.30 mm (0.051 in)

Intake Manifold

Intake manifold flatness deformation tolerance

0.075 mm (0.003 in.)

Exhaust Manifold

Exhaust manifold flatness deformation tolerance

0.075 mm (0.003 in.)

Tappets

Hydraulic tappet outside diameters

11.994 mm +/- 0.06 mm (0.472 in +/- 0.002)

Valves

Intake valve face angle

45°30'

Exhaust valve face angle

45°30'

Intake Valve Head Diameter

32 mm (1.25 in.)

Exhaust Valve Head Diameter

29.4 mm (1.15 in.)

Intake Valve Stem Diameter

5.97 mm (0.235 in.)

Exhaust Valve Stem Diameter

5.96 mm (0.235 in.)

Intake Valve Guide Stem Clearance

Min

0.030 mm (0.0012 in.)

Max

0.060 mm (0.0024 in.)

Exhaust Valve Guide Stem Clearance

Min

0.040 mm (0.0016 in.)

Max

0.070 mm (0.0028 in.)

Valve Springs

Free Length

50.8 mm (2 in.)

Closed Valve

38 mm (1.49 in.)

Opened Valve

29 mm (1.14 in.)

Camshafts

Camshaft End Play

Max

0.350 mm (0.014 in.)

Min

0.150 mm (0.006 in.)

Outer Journal Diameter (at crankshaft)

25.95 mm +/– 0.01 mm (1.021 mm +/- .0004 in)

Inner Journal Diameter (at cylinder head)

26.00 mm + 0.015 mm (1.027 mm .0006 in)

Crankshaft Journal Clearance

Max

0.075 mm (0.003 in.)

Min

0.030 mm (0.0012 in)

Connecting Rods

Connecting Rod Diameter (Small End)

32 mm (1.26 in.)

Connecting Rod Diameter (Large End)

57.563 mm ( 2.266 in.)

Piston Pin

Diameter

32 mm (1.26 in.)

Length

70.7 mm - 71.00 mm (2.78 in — 2.79 in.)

Crankshaft

End Play

0.1 mm — 0.33 mm (0.004 in. — 0.013 in.)

Bearing Selection (Refer to 09 - Engine/Engine Block - Standard Procedure)

Engine Block

Cylinder Bore Internal Diameter

94 mm (3.700 in.)

Cylinder Bore Out-Of-Round

0.007 mm (0.0003 in.)

Oversized Piston

+0.40 mm (+0.015 in.)

Fuel System

Injection Pressure

1800 Bar

High Pressure Pump

CP1H

ECU

EDC17

Injectors

Piezo CRI 3.2

Glow Plugs

Make/Type

Bosch / GLP2 HS

Voltage

4.4V

Lubrication System

Oil Pump Outer Rotor End Play

Min

0.01 (0.0004 in.)

Max

0.09 (0.0036 in.)

Oil Pump Inner Rotor End Play

Max

0.01 mm (0.0004 in.)

Min

0.09 mm (0.0036 in.)

Oil Pump Outer Rotor to Body Diameter Clearance

Max

0.130 mm (0.052 in.)

Min

0.230 mm (0.0091 in)

Oil Pressure Relief Valve

Opening Pressure

5 Bar

Oil Pressure Valve Spring Free Length

46.8 mm (1.84 in)

Minimum Oil Pressure (Warm)

at Idle

0.7 Bar

at 3800 RPM

2.5 Bar

Cooling System

Thermostat Opening Temperature

90°C +/- 2 (194°F +/-2)

Pressure Cap Setting

1.2 Bar

Engine Oil

Specification (Refer to 04 - Vehicle Quick Reference/Capacities and Recommended Fluids - Description)

Coolant

Specification (Refer to 04 - Vehicle Quick Reference/Capacities and Recommended Fluids - Description)


Cylinder Head Gasket Selection

 

Millimeters

Inches

DISTANCE FROM PISTON AT TDC TO CYLINDER BLOCK

0.300 — 0.399

0.0119 — 0.0158

CYLINDER HEAD GASKET THICKNESS

1.10

0.0434

PISTON CLEARANCE

0.700–0.800

0.0276 —0.0315

 

DISTANCE FROM PISTON AT TDC TO CYLINDER BLOCK

0.400 — 0.499

0.0158 — 0.0197

CYLINDER HEAD GASKET THICKNESS

1.20

0.0473

PISTON CLEARANCE

0.701–0.800

0.0276 —0.0315

 

DISTANCE FROM PISTON AT TDC TO CYLINDER BLOCK

0.500 — 0.600

0.0197 — 0.0237

CYLINDER HEAD GASKET THICKNESS

1.30

0.0512

PISTON CLEARANCE

0.700–0.800

0.0276 —0.0315

TORQUE

TORQUE


ENGINE BLOCK

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Air Temp/Pressure Sensor

12

106

Balance Shaft Bolts

33

24

Connecting Rod Bearing Cap Bolts

(Refer to 09 - Engine/Engine Block/ROD, Piston and Connecting - Installation)

Dipstick Tube Bolt (block)

33

24

Dipstick Tube Bolt (sump)

11

97

Engine Block Plug

30

22

Engine Mount Bolts

54

40

Lower Oil Pan Bolts

(Refer to 09 - Engine/Lubrication/PAN, Oil - Installation)

Main Bearing Cap Bolts

(Refer to 09 - Engine/Engine Block/CRANKSHAFT - Installation)

Oil Cooler Bolts

12

106

Oil Cooler Coolant Adapter Tube at Oil Filter Housing Bolt

11

97

Oil Cooler Coolant Tube Bolts

15

133

Oil Drain Plug

54

40

Oil Filter Cap

25

18

Oil Filter Housing Bolts

33

24

Oil Jet Bolt

11

97

Oil Pickup Tube Bolt

15

133

Oil Pressure Sensor

14

124

Oil Temperature Sensor

20

177

Upper Oil Pan (M6 bolt)

15

133

Upper Oil Pan (M8 bolt)

32

24

Wire Harness Support Bracket Bolt

45

33


CYLINDER HEAD

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Camshaft Bearing Cap Bolts

11

97

Camshaft Position Sensor Bolt

11

97

Camshaft Sprocket Bolt

80

59

Cylinder Head Bolts

(Refer to 09 - Engine/Cylinder Head - Installation)

Cylinder Head Cover Bolts

11

97

EGR Air Flow Control Valve Bolts

11

97

EGR Cooler Manifold Nuts

25

18

EGR Cooler Manifold Elbow Bolt

11

97

EGR Cooler Manifold Support Bracket Bolts

45

33

EGR Cooler Support Bracket Bolts

25

18

Exhaust Manifold Nuts

36

27

Front Camshaft Journal Bolts

11

97

Fuel injector Bolt

33

24

Fuel Rail Nuts

24

18

Fuel Tubes at Fuel Injector

28

20

Fuel Tubes at Fuel Rail

5 + 75°

44 + 75°

Glow Plugs

14

124

High Pressure Fuel Line Bracket Bolt

15

133

High Pressure Fuel Feed Line at Fuel Rail

5 + 75°

44 + 75°

High Pressure Fuel Feed Line at the High Pressure Pump

28

20

Intake Manifold Nuts

(Refer to 09 - Engine/Manifolds/MANIFOLD, Intake - Installation)

Turbocharger Nuts

25

18

Turbocharger Adapter (oil feed line to engine block connection)

54

40

Turbocharger Brace Bolts

32

24

Turbocharger Oil Feed Line at Engine Block

32

24

Turbocharger Oil Feed Line Nipple at Engine Block

54

40

Turbocharger Oil Feed Line Banjo Bolt at the Turbocharger

25

18

Turbocharger Oil Return Line Bolts

15

133

Vacuum Tube Nut

11

97


FRONT ENGINE

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Crankshaft Pulley Bolt

32

24

Crankshaft Sprocket Bolt

100 + 120°

74 + 120°

Front Cover Bolts

33

24

Fuel Quantity Solenoid Bolts

7

62

High Pressure Fuel Pump Blocker Nuts

25

18

High Pressure Fuel Pump Nuts

25

18

High Pressure Fuel Pump Sprocket Nut

88

65

Inner Front Cover Bolts

11

97

Outer Front Cover Bolts (lower)

8

71

Outer Front Cover Bolts (upper)

8

71

Timing Belt Tensioner Bolt

28

21

Water Pump Bolts

32

24


REAR ENGINE

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Crankshaft Sensor Bolt

11

97

CKP Cover Plate Bolts

15

133

Flex Plate (ATX)

(Refer to 09 - Engine/Engine Block/FLEXPLATE - Installation)

Rear Seal Cover Bolts

15

133

Trans Adapter Plate (allen bolts)

79

58

Trans Adapter Plate (hex bolt)

69

51


ACCESSORY DRIVE

DESCRIPTION N·m Ft. Lbs. In. Lbs.

A/C Compressor Bolts

28

21

A/C Compressor Nuts

28

21

A/C Compressor/Generator Bracket Bolts

45

33

Accessory Drive Belt Tensioner Bolt

45

33

Accessory Drive Idler Pulley Bolt

45

33

Front Engine Lifting Bracket Bolts

68

50

Generator Bolts

33

24

Power Steering Pump Bolts

33

24

Power Steering Pump Pulley Bolts

33

24

Viscous Fan Drive Pulley Bolts

45

33

REMOVAL

REMOVAL

  1. Disconnect the negative and positive battery cables.

  2.  
  3. Remove the battery.

  4.  
  5. Recover the refrigerant (Refer to 24 - Heating and Air Conditioning/Plumbing - Standard Procedure) .

  6.  
  7. On manual transmission models, remove the shiftier level (Refer to 21 - Transmission and Transfer Case/Manual/LEVER, Shift - Removal) .

  8.  
  9. Remove the air cleaner body (Refer to 09 - Engine/Air Intake System/BODY, Air Cleaner - Removal) .

  10.  
  11. Remove the turbocharger air inlet tube at turbo.

  12.  
  13. Remove the right side Charge Air Cooler (CAC) hose (1).

  14.  
  15. Raise and support the vehicle (Refer to 04 - Vehicle Quick Reference/Hoisting - Standard Procedure) .

  16.  
  17. Remove the front lower splash shield.

  18.  
  19. Drain the coolan (Refer to 07 - Cooling - Standard Procedure)

  20.  
  21. Drain the engine oil.

  22.  
  23. Using a new copper sealing washer, tighten oil drain plug to 54 N·m (40 ft. lbs.).

  24.  
  25. Remove the transmission skid plate.

  26.  
  27. Remove the catalytic converter (Refer to 11 - Exhaust System/CONVERTER, Catalytic - Removal) .


  28.  
  29. Remove the coolant recovery bottle (Refer to 07 - Cooling/Engine/BOTTLE, Coolant Recovery - Removal) .

  30.  
  31. Disconnect the engine harness connectors at right side firewall.

  32.  
  33. Disconnect the coolant hoses (1) from the heater core.

  34.  
  35. Disconnect the upper radiator hose at radiator.

  36.  
  37. Remove the fan assembly (Refer to 07 - Cooling/Engine/FAN, Cooling - Removal) .

  38.  
  39. Remove the serpentine belt (Refer to 07 - Cooling/Accessory Drive/BELT, Serpentine - Removal) .


  40.  
  41. Remove the left side Charge Air Cooler (CAC) hose (1) at EGR air flow control valve.

  42.  
  43. Remove the left side charge air cooler hose at cooler.


  44.  
  45. Remove the generator (Refer to 08 - Electrical/8F - Engine Systems/Charging/GENERATOR - Removal) .

  46.  
  47. Remove the A/C compressor (Refer to 24 - Heating and Air Conditioning/Plumbing/COMPRESSOR, A/C - Removal) .


  48.  
  49. Remove the A/C suction and liquid line from the condenser.

  50.  
  51. Remove the A/C suction and liquid lines from the evaporator.

  52.  
  53. Remove and discard gasket/O-ring seals and install protective caps over openings.


  54.  
  55. Remove the lower radiator hose (3) at radiator.


  56.  
  57. Remove the power steering pump pulley (1).


  58.  
  59. Remove the power steering pump (1) and position aside.


  60.  
  61. Disconnect the Camshaft Position Sensor (CMP) harness connector (1).


  62.  
  63. Disconnect the fuel injector harness connectors.


  64.  
  65. Disconnect the oil temperature sensor harness connector (1).


  66.  
  67. Disconnect the oil pressure switch harness connector (1).


  68.  
  69. Disconnect the fuel pressure sensor harness connector (1).

  70.  
  71. Disconnect the fuel pressure regulator harness connector (3).


  72.  
  73. Disconnect the turbocharger actuator connector.

  74.  
  75. Disconnect the EGR airflow control valve harness connector.

  76.  
  77. Disconnect the IAT/BPS harness connector.

  78.  
  79. Disconnect the ground strap between the cowl and hood.

  80.  
  81. Disconnect the glow plug harness connectors.

  82.  
  83. Position aside the upper engine harness.

  84.  
  85. Disconnect the brake booster vacuum hose.



    NOTE:

    Starter shown for a manual transmission.


  86.  
  87. Remove the starter (Refer to 08 - Electrical/8F - Engine Systems/Starting/STARTER - Removal) .


  88.  
  89. Disconnect the fuel supply and return tubes to high pressure pump.

  90.  
  91. Disconnect the fuel rail return line (1).

  92.  
  93. Disconnect the multi-sensor jumper harness connector (2).

  94.  
  95. Remove bolt, and the engine ground cable at engine block.

  96.  
  97. Remove the crankshaft position sensor (Refer to 14 - Fuel System/Fuel Injection/SENSOR, Crankshaft Position - Removal) .



    NOTE:

    The plastic clip that secures the transmission oil cooler lines to oil pan stud/bolt is a one time use clip that need to be replace each time the line is removed.


  98.  
  99. On automatic transmission models, remove the transmission cooler line (1) from oil pan stud (2) and discard clip (3).

  100.  
  101. Remove the torque converter to flex plate bolts.

  102.  
  103. On manual transmission models, remove the transfer skid plate.

  104.  
  105. On manual transmission models, remove the manual transmission (Refer to 21 - Transmission and Transfer Case/Manual - Removal) .


  106.  
  107. Remove the bell housing bolts.


  108.  
  109. Remove the nut from the left engine mount.

  110.  
  111. Remove the nut from the right engine mount.

  112.  
  113. Install a suitable engine lifting device.

  114.  
  115. Remove the engine.

  116.  

INSTALLATION

INSTALLATION


  1. Install the engine.

  2.  
  3. Remove the engine lift.

  4.  
  5. Install the right engine mount nut. Tighten nut to 54 N·m (40 ft. lbs.).

  6.  
  7. Install the left engine mount nut. Tighten nut to 54 N·m (40 ft. lbs.).


  8.  
  9. Install the bell housing bolts:

    • Tighten upper bolts to 41 N·m (30 ft. lbs.).
    • Tighten lower bolts to 54 N·m (40 ft. lbs.).
    • Tighten collar bolts to 68 N·m (50 ft. lbs.).

  10.  
  11. Install the transmission oil line bracket at the oil pan.


  12.  
  13. On manual transmission models, install the manual transmission (Refer to 21 - Transmission and Transfer Case/Manual - Installation) .

  14.  
  15. On manual transmission models, install the water and fuel separator (Refer to 14 - Fuel System/Fuel Delivery/SEPARATOR and FILTER, Fuel and Water - Installation) .

  16.  
  17. On manual transmission models, install the transfer skid plate.

  18.  
  19. Install the torque converter to flex plate bolts. Tighten bolts to 31 N·m (23 ft. lbs.).


  20.  
  21. Install the crankshaft position sensor (Refer to 14 - Fuel System/Fuel Injection/SENSOR, Crankshaft Position - Installation) .

  22.  
  23. Install the engine ground cable at engine block.

  24.  
  25. Connect the fuel rail return line.

  26.  
  27. Connect the fuel supply and return lines to high pressure pump.

  28.  
  29. Install the starter (Refer to 08 - Electrical/8F - Engine Systems/Starting/STARTER - Installation) .


  30.  
  31. Connect the brake booster vacuum hose.

  32.  
  33. Position the engine wiring harness.

  34.  
  35. Connect the glow plug harness connectors.

  36.  
  37. Connect the ground strap between the cowl and hood.


  38.  
  39. Connect the fuel quantity solenoid.

  40.  
  41. Connect the IAT/BPS harness connector (1).

  42.  
  43. Connect the EGR airflow control valve harness connector.

  44.  
  45. Connect the turbocharger actuator connector.


  46.  
  47. Connect the fuel pressure regulator harness connector (3).

  48.  
  49. Connect the fuel pressure sensor harness connector (1).


  50.  
  51. Connect the oil pressure switch harness connector (1).


  52.  
  53. Connect the oil temperature sensor harness connector (1).

  54.  
  55. Connect the coolant temperature sensor harness connector.

  56.  
  57. Connect the EGR bypass valve harness connector.


  58.  
  59. Connect the fuel injector harness connectors.


  60.  
  61. Connect the Camshaft Position Sensor (CMP) harness connector (1).

  62.  
  63. Connect the EGR valve harness connector.


  64.  
  65. Install the power steering pump (1). Tighten the bolts to 33 N·m (24 ft. lbs.).


  66.  
  67. Install the power steering pump pulley (1). Tighten bolts to 33 N·m (24 ft. lbs.).


  68.  
  69. Install the lower radiator hose at radiator.


  70.  
  71. Remove protective caps and lubricate install new gasket/O-ring seals.

  72.  
  73. Install the A/C suction and liquid lines to the expansion valve. Tighten the nut to 8 N·m (70 in. lbs.).

  74.  
  75. Install the A/C suction and liquid line from the condenser. Tighten the nuts to 23 N·m (17 ft. lbs.).


  76.  
  77. Install the A/C compressor (Refer to 24 - Heating and Air Conditioning/Plumbing/COMPRESSOR, A/C - Installation) .

  78.  
  79. Install the generator (Refer to 08 - Electrical/8F - Engine Systems/Charging/GENERATOR - Installation) .


  80.  
  81. Install the left side charge air cooler hose at cooler.

  82.  
  83. Install the left side charge air cooler hose at EGR air flow control valve.


  84.  
  85. Install the serpentine belt (Refer to 07 - Cooling/Accessory Drive/BELT, Serpentine - Installation) .

  86.  
  87. Install the fan assembly (Refer to 07 - Cooling/Engine/FAN, Cooling - Installation) .

  88.  
  89. Connect the upper radiator hose at radiator.

  90.  
  91. Install the coolant hoses (1) to the heater core.

  92.  
  93. Connect the engine harness connectors at right side firewall.

  94.  
  95. Install the coolant recovery bottle (Refer to 07 - Cooling/Engine/BOTTLE, Coolant Recovery - Installation) .


  96.  
  97. Install the left front wheel house splash shield (Refer to 23 - Body/Exterior/SHIELD, Splash - Installation) .

  98.  
  99. Install the catalytic converter (Refer to 11 - Exhaust System/CONVERTER, Catalytic - Installation) .

  100.  
  101. Install the transmission skid plate.

  102.  
  103. Install the front lower splash shield.

  104.  
  105. Install the right side charge air cooler hose.

  106.  
  107. Install the turbocharger air inlet tube at turbocharger.

  108.  
  109. Install the air cleaner body (Refer to 09 - Engine/Air Intake System/BODY, Air Cleaner - Installation) .

  110.  
  111. On manual transmission models, install the shiftier lever (Refer to 21 - Transmission and Transfer Case/Manual/LEVER, Shift - Installation) .

  112.  
  113. Fill the coolant (Refer to 07 - Cooling - Standard Procedure) .

  114.  
  115. Fill the with recommended engine oil.

  116.  
  117. Charge the A/C system (Refer to 24 - Heating and Air Conditioning/Plumbing - Standard Procedure) .

  118.  
  119. Install the battery.

  120.  
  121. Connect the positive and negative battery cables.

  122.  
  123. Start the engine and check for leaks.

  124.  

SPECIAL TOOLS

SPECIAL TOOLS

1023 - Puller

Originally Shipped In Kit Number(s) 8678.
10368 - Set, Universal Protective Cap
8534B - Fixture, Driveline Support

Originally Shipped In Kit Number(s) 8534, 8534B, 8849, 9565.
9937-1 - Installer, Seal

Originally Shipped In Kit Number(s) 9937.
9937-2 - Guide, Seal

Originally Shipped In Kit Number(s) 9937.
C-3339A - Set, Dial Indicator

Originally Shipped In Kit Number(s) 9202.
MD998772A - Compressor, Valve Spring

Originally Shipped In Kit Number(s) 8678, 8853, 8854.
MD998772A-15 - Adapter

Originally Shipped In Kit Number(s) 8678, 8853, 8854.
VM.10010 - Adapter, Compression Test
VM.10012 - Balance Shaft Split Gear Align
VM.10334 - Tool, Exhaust Manifold Alignment
VM.10335 - Installer, Front Crankshaft Oil Seal
VM.1055 - Locking Tool

Originally Shipped In Kit Number(s) 9599.
VM.1057 - Installer, Seal

Originally Shipped In Kit Number(s) 9599.
VM.1058 - Remover, Seal

Originally Shipped In Kit Number(s) 9599.
VM.9990 - Tool, Front And Rear Seal
VM.9991 - Alignment Tool, Camshaft Sprocket
VM.9992 - Adapter, 90 Degree ATDC
VM.9993 - Installer, Crankshaft Rear Oil Seal