Dodge Sprinter. Manual - part 218

(11) Install the torque converter access plate. Refer

to (Refer to 21 - TRANSMISSION/TRANSAXLE/AU-
TOMATIC - NAG1 - INSTALLATION) for correct
sequence and torque specification.

(12) Install the transmission cooler lines to trans-

mission. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - NAG1 - INSTALLATION) for
correct sequence and torque specification.

(13) Connect the engine valley drain hose to the

transmission (Fig. 5).

(14) Install transmission electrical connector and

shifter hardware. Refer to (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/AUTOMATIC - NAG1 - INSTAL-
LATION)

for

correct

sequence

and

torque

specification.

(15) Install the steering gear and tighten in two

stages. 25 N·m (18.5 lbs. ft.), then 45 N·m (33 lbs. ft.)
plus 90°.

(16) Install the starter.
(17) Connect the ground strap (left side).
(18) Align and install the exhaust and bracket

(Refer to 11 - EXHAUST SYSTEM/EXHAUST PIPE -
INSTALLATION).

(19) Lower the vehicle.
(20) Install the lower heater housing and filter.
(21) Install the air inlet hose, CCV breather and

CCV heater at the turbocharger (Fig. 4).

(22) Connect the coolant supply and return hoses.
(23) Connect the brake booster vacuum hose at the

vacuum pump.

(24) Connect the fuel lines at the filter assembly

(Fig. 9).

(25) Connect the power steering hoses.
(26) Install the radiator/charge air cooler and

hose(s) assemblies (Refer to 7 - COOLING/ENGINE/
RADIATOR - INSTALLATION).

(27) Install A/C condenser and fan assemblies Con-

nect the fan harness connector.

(28) Connect the refrigerant lines.
(29) Install a air conditioning receiver/drier (Refer

to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/RECEIVER / DRIER - INSTALLATION).

(30) Connect the upper and lower radiator hoses.
(31) Connect the transmission lines at the radia-

tor.

(32) Install air cleaner housing and connect the air

inlet duct and air flow sensor.

(33) Connect the charge air cooler hose at intake

manifold. (Refer to 9 - ENGINE/AIR INTAKE SYS-
TEM/AIR CLEANER HOUSING - INSTALLATION).

(34) Route the engine wiring harness inside the

vehicle and connect.

(35) Install the turbocharger heat shield.
(36) Install the front grille and fascia assembly.
(37) Connect the negative battery cable.
(38) Check and fill engine oil (Refer to LUBRICA-

TION & MAINTENANCE/FLUID TYPES - SPECIFI-
CATIONS).

Fig. 8 CRANKSHAFT POSITION SENSOR

1 - ENGINE BLOCK
2 - WIRING HARNESS CONNECTOR
3 - CRANKSHAFT POSITION SENSOR
4 - STARTER SOLENOID

Fig. 9 FUEL FILTER

1 - FUEL SUPPLY FROM TANK
2 - FUEL SUPPLY TO HIGH PRESSURE PUMP
3 - POWER STEERING RESERVOIR
4 - FUEL FILTER
5 - OIL FILTER
6 - WATER IN FUEL SENSOR

9 - 10

ENGINE

(39) Fill cooling system to proper level with the

appropriate coolant.

(40) Evacuate and recharge air conditioning.
(41) Check and refill all ancillary system fluid lev-

els.

(42) Start engine and inspect for leaks (Refer to 14

- FUEL SYSTEM - WARNING).

SPECIFICATIONS - TORQUE SPECIFICATIONS

2.7L DIESEL

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Crankcase Ventilation

Screw-Air Charge Distri-

bution Pipe to Air Charge

Distribution Panel

Cylinder Head

8m-Bolt- Cylinder Head to

Timing Case Cover

Bolt-Front Cover to Cylin-

der Head

124

12m-Bolt-Cylinder Head

to Crankcase (3 stages,

torque, torque angle,

torque angle)

60, 90°, 90°

44, 90°,90°

Crankcase, Timing Case

Cover, End Cover

Bolt-Crankshaft Bearing

Cap to Crankcase (2

stages, torque, torque an-

gle)

55, 90°

40, 90°

Bolt-End Cover to Crank-

case

Bolt-Timing Case Cover

to Crankcase

Plug-Coolant Drain to

Crankcase

Oil Pan

6m-Bolt-Oil Pan to Crank-

case

8m-Bolt-Oil Pan to Crank-

case

Bolt-Oil Pan to End Cover

Bolt-Oil Pan to Timing

Case Cover

Bolt-Oil Pan to Transmis-

sion Bell Housing

Plug-Oil Pan to Oil Drain

Connecting Rod

ENGINE

9 - 11

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Bolt-Connecting Rod Cap

to Connecting Rod (3

stage, 1&2 torque, 1

torque angle)

5,25,90°

44,221, 90°

Crankshaft

Bolt-Crankshaft Bearing

Cap (2 stage, 1 torque, 1

torque angle

55,90°

40.5, 90°

Flywheel, Driven Plate, Vibration Damper, Starter Ring Gear

8.8m-Bolt-Central Bolt of

Vibration Damper (2

stage, 1 torque, 1 torque

angle)

200,90°

147.5, 90°

10.9m-Bolt-Central Bolt of

Vibration Damper (2

stage, 1 torque, 1 torque

angle)

325,90°

240, 90°

Bolt-Stretch Shank for

Flywheel or 2 Mass Fly-

wheel to Crankshaft (2

stage, 1 torque, 1 torque

angle)

45,90°

33, 90°

Turbo Charger

Bolt-Oil Feed Line to Cyl-

inder Head

9/22

80-194

Bolt-Oil Feed Line to Tur-

bo Charger

Bolt-Turbo Charger Sup-

port

Bolt-Turbo Charger Sup-

port to Crankcase

177

Bolt-Oil Outlet Line to

Turbo Charger

Connection-Flange of Ex-

haust Manifold to Turbo

Charger

Connection-Turbo Charger

to Front Catalytic Con-

verter

Charge Air Pipe/Charge Air Cooling

Bolt-Charge Air Distribu-

tion Pipe

141

Bolt-Inlet Port Shut Off

Positioning Motor to Air

Charge Distribution Pipe

Bolt-Support to Charge

Air Distribution Pipe

177

Bolt-Support to Engine

Bracket

9 - 12

ENGINE

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Clamp-Charge Air Pipes/

Hoses

Belt Tensioning Device

Bolt-Guide Pulley to Cool-

ant Pump

Bolt-Guide Pulley to Tim-

ing Case Cover

Bolt-V-Belt Tensioning De-

vice to Tensioning Pulley

26.5

Bolt-V-Belt Tensioning De-

vice to Timing Case Cov-

Exhaust Manifold

Nut-Exhaust Manifold at

Cylinder Head

Position Sensor

Nut/Bolt-Camshaft Posi-

tion Sensor to Cylinder

Head Cover

Nut/Bolt-Crankshaft Posi-

tion Sensor to Engine

Block

Pre-Glow System

Cylinder Head to Glow

Plug

106

Starter

Bolt-Starter to Crankcase

Nut-Connection of Circuit

124

Nut-Connection of Circuit

Alternator

Bolt-Generator to Timing

Case Cover

Bolt-Generator to Cooler

Housing

Bolt-Cooler Housing of

Generator to Crankcase

177

Nut-B+ Circuit to Genera-

tor

13-18

115-159

Nut-D+ Circuit to Genera-

tor

Nut-Collar to V-Belt Pulley

Oil Pump

Bolt-Oil Pump to Crank-

case

133

Bolt-Oil Pipe to Crank-

shaft Bearing Cap

ENGINE

9 - 13

Content .. 216 217 218 219 ..