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GROUP TAB LOCATOR - Jeep

1. Fig 28 Check Ball Locations 8060721 NOTE Refer to the Hydraulic Schematics for a visual aid in determining valve location operation and design SOLENOID SWITCH VALVE The Solenoid Switch Valve SSV controls the direc tion of the transmission fluid when the L R TCC sole noid is energized The Solenoid Switch Valve controls line pressure from the LR TCC solenoid In 1st gear the SSV will be in the downshifted position thus directing fluid to the L R clutch circuit In 2nd 3rd 4th and fifth gears the solenoid switch valve will be in the upshifted position and directs the fluid into the torque converter clutch TCC circuit When shifting into 1st gear a special hydraulic sequence is performed to ensure SSV movement into the downshifted position The L R pressure switch is monitored to confirm SSV movement If the move KJ VALVE BODY Continued ment is not confirmed the L R pressure switch does not close 2nd gear is substituted for 1st DTC will be set after three unsuccessful attempts are made to get into 1st gear in one given key start MANUAL VALVE The manual valve is a relay valve The purpose of the manual valve is to direct fluid to the correct cir cuit needed for a specific gear or driving range The man
2. 80ba79d0 Fig 2 Torque Converter Pressure Locations TCC RELEASE TO COOLER TCC APPLY FROM COOLER LINE PRESSURE SENSOR akon To determine the line pressure there are two avail able methods The DRB scan tool can be used to read line pressure from the line pressure sensor The second method is to install Line Pressure Adapter 8259 Fig 4 into the transmission case and then install the pressure gauge and the original sensor into the adapter This will allow a comparison of the DRB readings and the gauge reading to determe the accuracy of the line pressure sensor The DRB line pressure reading should match the gauge reading within 10 psi order to access any other pressure tap locations the transmission oil pan must be removed the pres sure port plugs removed and Valve Body Pressure Tap Adapter 8258 A Fig 5 installed The extensions supplied with Adapter 8258 A will allow the installa tion of pressure gauges to the valve body Refer to Fig 3 for correct pressure tap location identifica tion 2c 80ba79d1 Fig 3 Pressure Tap Locations 4 ES OM D lt 2229 SS YN D 2 e T 806072 4 Line Pressure Adapter 8259 LINE PRESSURE SENSOR PORT LINE PRESSURE SENSOR TOOL 8259 PRESSURE TAP AUTOMATIC TRANSMISSION 545RFE 21 5
3. 7 27 HOSE CLAMPS Continued CAUTION A number or letter is stamped into the tongue of constant tension clamps If replacement is necessary use only a original equipment clamp with matching number or letter Fig 15 OPERATION HOSE CLAMPS The spring type hose clamp applies constant ten sion on a hose connection To remove a spring type hose clamp only use constant tension clamp pliers designed to compress the hose clamp 80b76ee Fig 15 Spring Clamp Size Location 1 SPRING CLAMP SIZE LOCATION KJ ELECTRONIC CONTROL MODULES TABLE OF CONTENTS page ENGINE CONTROL MODULE DESCRIPTION 222222552424 eee tarasi 1 OPERATION y Ro cR es a 1 STANDARD PROCEDURE PCM ECM SKIM PROGRAMMING DIESEL 2 ENGINE CONTROL MODULE DESCRIPTION The ECM is located in the left side of engine com partment attached to the left inner fender behind the battery Fig 1 80cc7aa6 Fig 1 ENGINE CONTROL MODULE ECM REMOVAL INSTALL ECM ELECTRICAL CONNECTORS ENGINE CONTROL MODULE ECM ECM MOUNTING BRACKET ECM MOUNTING BRACKET MOUNTING STUDS MOUNTING BRACKET RETAINING NUTS OPERATION The ECM has been programmed to monitor differ ent circuits of the diesel fuel injection system This AON ELECTRONIC CONTROL MODULES 8E 1 page REMOVAL ese 4 INSTALLATION 4 monitoring is called on board
4. 00681 IV NO 22 440 22 sadsaunssaud 08 31 811 55 991 66 10S 29 41 VIA H1 NOILSOd H1NIASS 1 T TE puni m 14 Q31VA3 13 7 HOSN3S Saud 3NIT Sd 10S TOHLNOO S3Hud SOd av I1O313S LEIQWA SIN HOLIMS S3Hd Sd 1 3905539 9 1 YALYAANOD 99 HOLfYIO 19 HOLNTO 2 3SH3AdH MOT H1 25 2 c L 0599 14 15914 Y AUTOMATIC TRANSMISSION 545RFE AUTOMATIC TRANSMISSION 545RFE Continued 21 12 G M WOHJ HV3O LSHIJ NI MO T4 Or TDVHGAH NOOO 44090 an SW acaisaunssaua 08 51 811 66 591 06 5 27 14 HOSN3S S3ud aNri sd1 103 13S LETTIW SIN 19 H31H3ANOO 29 HO1 10 17 29 an ET HOLfTTO 02 5 4 8 A TY tA 22222 Yaa an 999 9999 In 0020608 VC To Tee IOS IOHLNOO S3Hd SOd YHOLVINANDOV 9V f cor mor a Nuniad HOLIMS S3Hd Sd JYNSS3AYd 1d 10 8
5. 3SH3A3H 1 9 6 dq 151 MOILSOLRV HO MOT uaria 21 25 AUTOMATIC TRANSMISSION 545RFE AUTOMATIC TRANSMISSION 545RFE Continued 78790208 5 NO99 440992 isd saunssaud 09 811 66 6901 66 22 22 22 am ME an NN YOLV1ND3Y NANAH PARAL INN d A 22 22 at eee ET OEE ET TO A 29 H s H H H H H H 11 H H Li Li 4 H H 14 Jock dor id adi 1 9E rovi HosNas 3Nri Sd1 10S 10H1NOO S3Hd S9d ns WIE 19313S LInW SW HOLIMS S3Hd Sd 553 4 14 70 H31H3ANOO 90 Ho1v1nWnoov ov c AUS HOLATO 58 HOLNTO PUZ 9ze lt MO1 Y1 5 6 Y AUTOMATIC TRANSMISSION 545RFE AUTOMATIC TRANSMISSION 545RFE Continued 21 26 94951194 GaNOO3S NI
6. 25 Alaa 16814 21 13 AUTOMATIC TRANSMISSION 545RFE AUTOMATIC TRANSMISSION 545RFE Continued GNODAS NI 49190808 cosy 59 43095 dn SW oora lt 08 9 18 11 56 991 56 zad cady 7 1 3 oe n Hall 99 747 25 Sd 54 i Lv 12 i 21113 2 dd 14 14 AN3A A E ovE 3 ove 3 HOsN3s ANIT Sd1 105 TOHLNOO SaYd SOd 109198 07 5 HOLIMS S3tid Sd 5 dVl 5 14 H31H3ANOO 0D HOLWINWNODOV oV ee HO1f115 Up or 10 go 51 2 Ala a 2 6 2 TN H HOLN19 Puz oc 3SuaAa3H MOT u1 99 o 5 2 HV39 GNOIDAS DITINVYGAH 9220808 59 44090 ISd e3unss3ud 29155 1 Nanda xA Sb Sd Sd IN3A A Q3IVA3 T3 May SNIT Sd1 105 s38d sOd E 190313s L InW SW HOLIMS S3Hd Sd 3uriss
7. 24 INSTALLATION COOLING FAN 18 INSTALLATION educ ED 22424 25 INSTALLATION COOLING FAN SUPPORT 18 RADIATOR PRESSURE CAP COOLANT SYSTEM HOSES DESCRIPTION rota tana bei i 25 REMOVAL OPERATION aite e tens Asc ache 25 REMOVAL UPPER RADIATOR HOSE 18 DIAGNOSIS AND TESTING REMOVAL HEATER CORE HOSES 18 DIAGNOSIS AND TESTING COOLING INSTALLATION SYSTEM PRESSURE 25 INSTALLATION UPPER RADIATOR HOSE 19 DIAGNOSIS AND TESTING PRESSURE INSTALLATION HEATER CORE HOSES 19 RELIEF TEST REIS 25 ENGINE COOLANT TEMP SENSOR CLEANING 26 DESCRIPTION 19 INSPEGIION 54044840 26 OPERATION aA E 19 HOSE CLAMPS REMOVAL 20 DESCRIPTION HOSE CLAMPS 26 INSTALLATION 20 OPERATION HOSE CLAMPS 27 ENGINE COOLANT THERMOSTAT DESCRIPTION m Rm es 20 COOLANT 1 DO NOT remove radiator cap first With engine STANDARD PROCEDURE STANDARD PROCEDURE DRAINING COOLING SYSTEM WARNING DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAINCOCK WITH SYSTEM HOT AND UNDER PRESSURE SERIOUS BURNS FROM COOLANT CAN OCCUR cold raise vehide on a hoist and locate radiator draincock NOTE Radiator draincock is located on the Right lower side of radiator facing to rear
8. 24 OPERATION 25 REMOVAL eee Ee 25 INSTALLATION 25 8100abce Fig 1 CRANKSHAFT POSITION SENSOR INSTALLATION 1 Lubricate o ring on crankshaft position sensor and install sensor in engine block Fig 2 2 Install crankshaft position sensor retaining bolt Fig 2 Torque bolt to 10 8N m 3 Connect crankshaft position sensor electrical connection KJ FUEL INJECTION 14 19 CRANKSHAFT POSITION SENSOR Continued 80 063 Fig 2 CRANKSHAFT POSITION CKP SENSOR REMOVAL INSTALL 1 RETAINING BOLT 2 WASHER 3 CRANKSHAFT POSITION CKP SENSOR 4 ENGINE BLOCK 4 Connect exhaust pipe to turbocharger down pipe Torque bolts to 32 4N m 5 Lower vehicle from hoist 6 Connect negative battery cable ACCELERATOR PEDAL POSITION SENSOR DESCRIPTION The Accelerator Pedal Position Sensor is a variable resistor that provides the ECM with an input signal voltage Fig 3 The signal represents throttle blade position As the position of the accelerator pedal changes the resistance of the sensor changes Fig 4 REMOVAL 1 Disconnect negative battery cable 2 Disconnect accelerator pedal position sensor electrical connector Fig 5 3 Remove accelerator pedal assembly mounting bolts Fig 5 4 Open accelerator pedal position sensor assem bly and disconnect accelerator cable Fig 6 5 Remove
9. HOSN3S 53 ANIT Sd71 105 TOHINOO S3Hd SOd ov 109135 1 5 HOLIMS 53 4 54 SYNSS3AYd 1d HALYAANOD 99 YOLVINANDOV 9V HOLNT9 19 3SH3A3H OH 5 MO T H1 8 H3AO Q33dS M OL LAIHS 30018 5 6 2 2 1 Y AUTOMATIC TRANSMISSION 545RFE AUTOMATIC TRANSMISSION 545RFE Continued 21 10 9ejpoeog HO 4 15814 NI 2I TOVHGAH 2109 INN dWns ISd Ss3unissaud 08 61 811 66 691 08 eee ALIIWNO 1 6 LOALOYd OL 7105 99 91 ASS VIA e 7 bra l 2 s an Cu RR RR 9999994 86640068 i N Li 11 14 IN3A A HOSN3S S3Hd 1 541 105 10H1NOO 53 504 108135 11001 511 HOLIMS 53 4 54 3HfiSS3Hd 1d H31H3ANO2 09 1 HO1n19 19 an H LNTO Puz oz 3su3A3H MOT H1 29 9 N WOU 1Sul4 21 11 AUTOMATIC TRANSMISSION 545RFE AUTOMATIC TRANSMISSION 545RFE Continued 48090808 SIY 4 84140 15914 NI MOTA
10. NO 340 22 Ng EE Ee A fl t 4 4 15525558 14 19373 5 19 H31H3ANOO729 HOLN19 Utp Or an 3AIHdH3AO dO 2 2 1 2 5 1 SOWA ANOIS INJA A MO JH3AO 031 313 5 E ov HOSN3S Saud 541 IOS IOHLINOO S3Hd SOd HOLIMS S3Hd Sd B 1 JUNSSAYd 1d E gt 1009A coc 21 17 AUTOMATIC TRANSMISSION 545RFE AUTOMATIC TRANSMISSION 545RFE Continued NI 85290808 INdH 0081 1v 64 saunssaud 08 51 811 58 691 8 22 2117 1111 222 nooo 4 22 2224 Alum uuu uuu ww e 14 10374S ILINN SW 1563 14 12 1 HOL 110 5 8 2 2 1 1 uv3o 193410 IN3A A MO TIJH3AO O31VA3 37 HOSN3S S3Hd SNIT Sd1 7106 1 S3Hd SOd 3 HOLIMS S3Hd Sd 1 208602 Y AUTOMATIC TRANSMISSION 545RFE AUTOMATIC TRANSMISSION 545RFE Continued 2
11. sa s3unssaud 08 55 85796 69196 1 Hebe ee ana 2 1 1 A uaria 22222227274 uA 272224 a 1 p MO IJH3AO Q3IVA3 T3 HOSN3S S3Hd 1 541 10S 1 5 4 504 COOLER ov 193 13S 8 LEIQW SIA HOLIMS S3Hd Sd dVL JUNSSAYd 1d E H31H3ANOO OO YOLVINWNNDOV OV 19 5 oo Puc Oc 5 5 dq 6 0 2 1 SOWA uvao Y AUTOMATIC TRANSMISSION 545RFE AUTOMATIC TRANSMISSION 545RFE Continued 21 24 219890808 LSL MOILSOLNV MOT TIVNNVI NI 0091 Lv an sw 90 91 IiSsd s34nss3ud 1 08 51 811 66 691 66 3ZIDH3N3 SCIONT 10 22123252 2222222223 N0 22 7 1 Ta Sd A bul H 6666664 i mor bree Ae 14 Q31VA3T37 HOSN3S S3Hd SNIT Sd1 10S 1 S3Hd SOd 10374S ILINW SW HOLIMS SAYd Sd 3HriSS3Hd 1d H31H3ANOO 00 HOLVINNNDOV 0V puc 9 HOLN19 19 81
12. 80 07429 Fig 18 Input Clutch Assembly Mounted 8260 1 INPUT CLUTCH ASSEMBLY 2 TOOL 8260 80007440 Fig 19 Measuring UD Clutch Clearance 1 TOOL C 3339 2 UNDERDRIVE CLUTCH PACK 23 Install the reverse clutch pack into the input clutch retainer Fig 17 24 Install the reverse reaction plate into the input clutch retainer 25 Install the reverse reaction plate selective snap ring into the input clutch retainer AUTOMATIC TRANSMISSION 545RFE 21 39 m CREAR 80 07447 Fig 20 Measuring OD Clutch Clearance 1 TOOL 3339 2 OD REV REACTION PLATE 26 Mount a dial indicator to the assembly push down on the clutch discs pull up on the reaction plate to ensure the plate is properly seated and zero the indicator against the reverse clutch discs Fig 21 Apply 20 psi of air pressure to the reverse clutch and record the dial indicator reading Measure and record Reverse clutch pack measurement in four 4 places 90 apart Take average of four measurements and compare with Reverse clutch pack clearance specification The correct clutch clearance is 0 58 1 47 mm 0 023 0 058 in Adjust as necessary Install the chosen snap ring and re measure to verify selection D S 80507446 Fig 21 Measuring Reverse Clutch Clearance 1 TOOL 3339 2 REVERSE CLUTCH PACK 21 40 AUTOMATIC TRANSMISSION 545RFE INPUT CLUTCH AS
13. eum Se COOLER 9990 08 25 35020 dNNS 1 08 51 841 06 691 66 G3ZIOH3N3 SCIONS OS ED EG ALIIWNO 1 6 LOALOYd OL 105 99 91 ASS VIA e A l Ep RR RR Sd Sd Sd E H 222213 rIzIZIITIIIIIIIIPTIITITU enfrirrIzzIII 14 14 14 LNSA A Q31VA3 137 YOSNAS Saud ANIT Sd1 10S SdHd SOd ov 193 74S ILINN SW HOLIMS 53 4 54 AYNSSAYd 1ld HOLNTO 47 09 3sH3A3H 9H E oo ov Oc 2 6 1 1 ajos t z 9 NH 2 c L uv3o 21 22 AUTOMATIC TRANSMISSION 545RFE AUTOMATIC TRANSMISSION 545RFE Continued 21 23 AUTOMATIC TRANSMISSION 545RFE AUTOMATIC TRANSMISSION 545RFE Continued 5990 08 x d o 54 IOWA 1 414 NI MO TH 0061 19 NO 55 44099 dAns
14. EXHAUST PIPE TO TURBO DOWNPIPE GASKET tailpipe assembly out of exhaust hanger Fig 3 3 EXHAUST PIPE RETAINING BOLT 4 Remove muffler and tailpipe assembly from 4 EXHAUST PIPE vehicle 80cdc88e Fig 1 EXHAUST PIPE REMOVAL INSTALLATION EXHAUST SYSTEM AND TURBOCHARGER 11 3 MUFFLER Continued INSTALLATION 1 Install muffler and tailpipe assembly in vehicle and attach to exhaust hangers Fig 3 2 Install muffler and tailpipe assembly to exhaust pipe retaining nuts Torque nuts to 32 4N m 3 Lower vehicle from hoist 80cdc895 Fig 2 EXHAUST PIPE HANGERS 1 EXHAUST PIPE 2 RUBBER EXHAUST HANGERS 3 TRANSMISSION CROSSMEMBER 22 80cd4be7 Fig 3 MUFFLER AND TAILPIPE ASSEMBLY 1 RETAINING NUT 3 MUFFLER AND TAILPIPE ASSEMBLY 2 ATTACHING STUD LOCATION 4 MUFFLER AND TAILPIPE HANGER LOCATIONS 11 4 HEAT SHIELDS DESCRIPTION Heat shields are needed to protect both the vehicle and the environment from the high temperatures developed by the catalytic converter The catalytic converter releases additional heat into the exhaust system Under severe operating conditions the tem perature increases in the area of the converter Such conditions can exist when the engine misfires or oth erwise does not operate at peak efficiency Fig 4 80b89850 Fig 4 Front and Rear Floor Pan Heat Shields Typical EXHAUST SYSTEM AND TURBOCHARGER
15. 5 Remove charge air cooler inlet hose from tubo charger and reposition out of way 6 Drain cooling system 7 Remove coolant recovery pressure container Refer to 7 COOLING ENGINE COOLANT RECOV ERY PRESS CONTAINER REMOVAL 8 Disconnect both EGR cooler coolant hoses at cooler Fig 12 9 Remove EGR valve to exhaust manifold retain ing nuts Fig 12 10 Remove EGR cooler to exhaust manifold retaining bolt Fig 12 11 8 EXHAUST SYSTEM AND TURBOCHARGER TURBOCHARGER Continued HC AMS y lt RN Ji D VN 15 gt KJ 80cdb6ed Fig 11 TURBOCHARGER INLET HOSE FROM AIR CLEANER 1 TURBOCHARGER INLET HOSE 2 AIR CLEANER HOUSING 3 TURBOCHARGER INLET HOSE 4 TURBOCHARGER 11 Reposition EGR cooler out of way 12 Remove exhaust manifold heat shield retain ing bolts and remove heat shield Fig 13 13 Disconnect turbocharger oil supply line at tur bocharger Fig 13 14 Raise vehicle on hoist 15 Disconnect exhaust pipe at turbocharger down pipe 16 Disconnect turbocharger oil return line at tur bocharger Fig 13 17 Lower vehicle 18 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 19 Remove viscous heater Refer to 24 HEAT ING amp AIR CONDITIONING PLUMBING ELEC TRIC COOLANT PUMP REMOVAL 20 Remove the thermostat housing Refer to 7 COOLING ENGINE ENGINE CO
16. 9 9 ENGINE 2 5L 2 8L TURBO DIESEL Continued DESCRIPTION Wm OT Pump 84 5 1 Structural Support to 45 1 33 Engine and Transmission Bolts 275 83 4 24 5 Transmission to Engine 62 Bolts Cylinder Head Cover 18 Intake Manifold Bolts Camshaft Timing Access 24 5 Bolts Camshaft Access Plugs Oil Separator Bolts Camshaft Position Sensor Bolt Boost Pressure Intake Air Temp Sensor Bolts Accessory Drive Bracket Bolts Accessory Drive Belt Idler Pulley Bolt Vacuum Line Fitting Bolt Fuel Pump Nuts Fuel Line Fittings at Pump Fuel Rail Retaining Bolts Inner Timing Belt Cover Bolts 8mm 10mm Outer Timing Belt Cover Bolts 3 3 3 3 Engine Mount Bracket to Cylinder Head Bolts Structural Support to Engine and Transmission Bolts Intake Inlet Tube Bolts Camshaft Sprocket Bolts Camshaft Timing Access Bolts 9 10 ENGINE ENGINE 2 5L 2 8L TURBO DIESEL Continued Timing Belt Idler Pulley Bolt Fuel Injection Pump Gear 88 3 Nut Fuel Injection Pump Retaining Nuts Thermostat Housing Bolt Turbocharger Oil Supply 24 5 18 Line Fitting Turbocharger Oil Return Line Bolts Exhaust Manifold Heat 24 5 18 Shield Exhaust Manifold Heatshield Bolts EGR Valve Nuts Valve Nuts 324 O 4 Pipe to EGR I Valve Bolts Turbocharger Downpipe 32 4 24 Nuts Turbocharger Bracket
17. SNAP RING FLAT REVERSE HUB SHAFT REVERSE CLUTCH REVERSE REACTION PLATE 10 SNAP RING SELECT 11 PLATE 12 DISC 13 OD CLUTCH 14 SNAP RING TAPERED 15 UD OD REACTION PLATE 16 SNAP RING FLAT 17 UD HUB SHAFT 18 BEARING NUMBER 2 18 Install the overdrive clutch pack into the input clutch retainer Fig 17 The overdrive steel separator plates can be identified by the lack of the half moon cuts in the locating tabs 19 Install the overdrive clutch wavy snap ring with the two tabbed ears into the input dutch retainer 20 Install the OD reverse reaction plate into the input clutch retainer The reaction plate is non direc tional Fig 17 21 Install the OD reverse reaction plate flat snap ring into the input clutch retainer 22 Mount a dial indicator to the assembly and zero the indicator against the OD reverse reaction plate Fig 20 Apply 20 psi of air pressure to the overdrive clutch and record the dial indicator read ing Measure and record OD clutch pack measure ment in four 4 places 90 apart Take average of four measurements and compare with OD clutch pack clearance specification Verify that the clutch clearance is 1 103 1 856 mm 0 043 0 073 in The reaction plate is not selective If the clutch clearance is not within specification replace the reaction plate along with all the friction and steel discs INPUT CLUTCH ASSEMBLY Continued
18. page CAMSHAFT POSITION SENSOR DESCRIPTION 1 OPERATION ta aide ee 2 REMOVAL eS LEG 2 INSTALLATION 2 GLOW PLUG DESCRIPTION 2 CAMSHAFT POSITION SENSOR DESCRIPTION The camshaft position CMP sensor is mounted in the top of cylinder head cover intake manifold at the rear of the engine Fig 1 Fig 2 The CMP sensor is a hall effect device 80047676 Fig 1 CAMSHAFT POSITION SENSOR IGNITION CONTROL 81 1 page OPERATION eee 2 REMOVAL 4 2 INSTALLATION 3 GLOW PLUG RELAY DESGRIPTION 5 lt lt xm 4 OPERATION 4 80424362 Fig 2 CAMSHAFT POSITION CMP SENSOR 1 CAMSHAFT POSITION CMP SENSOR 81 2 IGNITION CONTROL CAMSHAFT POSITION SENSOR Continued OPERATION The CMP sensor is a hall effect switch A tooth made of a ferromagnetic material is attached to the camshaft When this tooth passes the CMP sensor an electronic signal is created This signal is then sent to the engine control module ECM This signal is used by the ECM to determine which cylinder has just entered its compression phase REMOVAL 1 Disconnect negative battery cable 2 Remove engine cover Refer to 9 ENGINE COVER
19. Engine Start Up Mode The ECM uses the engine temperature sensor and the crankshaft position sensor engine speed inputs to determine fuel injection quantity Normal Driving Modes Engine idle warm up acceleration deceleration and wide open throttle modes are controlled based on all of the sensor inputs to the ECM The ECM uses 8E 2 ELECTRONIC CONTROL MODULES ENGINE CONTROL MODULE Continued these sensor inputs to adjust fuel quantity and fuel injector timing Limp In Mode If there is a fault detected with the accelerator pedal position sensor the ECM will set the engine speed at 1100 RPM Overspeed Detection Mode If the ECM detects engine RPM that exceeds 5200 RPM the ECM will set a DTC in memory and illu minate the MIL until the DTC is cleared After Run Mode The ECM transfers RAM information to ROM and performs an Input Output state check MONITORED CIRCUITS The ECM is able to monitor and identify most driveability related trouble conditions Some circuits are directly monitored through ECM feedback cir cuitry In addition the ECM monitors the voltage state of some circuits and compares those states with expected values Other systems are monitored indi rectly when the ECM conducts a rationality test to identify problems Although most subsytems of the engine control module are either directly or indirectly monitored there may be occasions when diagnostic trouble codes are not immediately identified For a
20. Fig 75 TIMING BELT AND SPROCKETS CAMSHAFT SPROCKETS INJECTION PUMP SPROCKET INJECTION PUMP SPROCKET RETAINING NUT TIMING BELT TIMING BELT TENSIONER RETAINING BOLT TIMING BELT TENSIONER TENSIONER ALIGNMENT PIN IDLER PULLEY CAMSHAFT SPROCKET RETAINING BOLT INSTALLATION 1 Install timing belt idler pulleys Torque bolts to 47 1N m 2 Install timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION 3 Install timing belt outer cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 4 Install vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER INSTAL LATION ENGINE 9 55 5 Install cooling fan support Refer to 7 COOL ING ENGINE RADIATOR FAN INSTALLATION 6 Install accessory drive belt Refer to 7 COOL ING ACCESSORY DRIVE DRIVE BELTS INSTAL LATION 7 Install cooling fan and fan drive viscous clutch assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH INSTALLATION 8 Install engine cover Refer to 9 ENGINE COVER INSTALLATION 9 Connect negative battery cable TIMING BELT CHAIN AND SPROCKET S REMOVAL CAUTION BEFORE REMOVING THE TIMING BELT THE ENGINE MUST BE PLACED AT 90 AFTER TDC FAILURE TO DO SO MAY RESULT IN VALVE AND OR PISTON DAMAGE DURING ASSEMBLY Refer to 9 ENGINE VALVE TIMING STANDARD PROCEDURE 1 Disconne
21. REMOVAL 3 Disconnect CMP sensor electrical Fig 3 4 Remove CMP sensor retaining bolt and remove sensor from cylinder head cover intake manifold Fig 3 connector 80d2d362 Fig 3 CAMSHAFT POSITION CMP SENSOR 1 CAMSHAFT POSITION CMP SENSOR INSTALLATION 1 Lubricate O ring on new CMP sensor and install in cylinder head cover intake manifold Fig 3 2 Install retaining bolts Torque to 10 8N m 3 Connect sensor electrical connector 4 Install engine cover Refer to 9 ENGINE COVER INSTALLATION 5 Connect negative battery cable KJ GLOW PLUG DESCRIPTION Glow plugs are used to help start a cold or cool engine Fig 4 The glow plugs will heat up and glow to heat the combustion chamber of each cylinder An individual glow plug is used for each cylinder Each glow plug is threaded into the left side of the cylinder head below the cylinder head cover intake manifold 80c46ef8 Fig 4 GLOW PLUG OPERATION Each glow plug will momentarily draw approxi mately 25 amps of electrical current during the ini tial key ON cyde This is on a cold or cool engine After heating the current draw will drop to approxi mately 9 12 amps per plug Total momentary cuurent draw for all four glow plugs is approximately 100 amps on a cold engine dropping to a total of approximately 40 amps after the plugs are heated Electrical operation of the glow plugs is
22. REMOVAL 1 Disconnect negative battery cable 2 Remove cylinder head Refer to 9 ENGINE CYLINDER HEAD REMOVAL 3 Raise vehicle on hoist 9 38 ENGINE PISTON amp CONNECTING ROD Continued 7N J9009 45 Fig 44 RING END GAP MEASUREMENT 1 FEELER GAUGE 19509 22 Fig 45 PISTON RING GROOVE CLEARANCE 4 Remove oil pan Refer to 9 ENGINE LUBRI CATION OIL PAN REMOVAL 5 Remove oil pump pickup tube Refer to 9 ENGINE LUBRICATION OIL PUMP REMOVAL 6 Remove balance shaft assembly Refer to 9 ENGINE VALVE TIMING BALANCE SHAFT REMOVAL 7 Remove top ridge of cylinder bores with a ridge reamer before removing pistons from cylinder block Be sure to keep top of pistons covered during this operation 8 Piston and connecting rods must be removed from top of cylinder block Rotate crankshaft so that each connecting rod is centered in cylinder bore KJ NOTE Be careful not to nick or scratch crankshaft journals 9 After removal install bearing cap on the mat ing rod and mark pistons with matching cylinder number when removed from engine block PISTON PIN REMOVAL 1 Secure connecting rods in a soft jawed vice 2 Remove 2 snap rings securing piston pin Fig 46 3 Push piston pin out of piston and connecting rod Fig 46 80c6c8fe Fig 46 PISTON AND CONNECTING ROD ASSEMBLY PISTON PIN PISTON SNAP RING CONNECTING ROD ALIGNMENT NUMBERS
23. shaft oil seal in rear main bearing support Fig 37 8011304 Fig 37 REAR CRANKSHAFT OIL SEAL INSTALLATION USING VM 1050 SPECIAL TOOL VM 1050 REAR MAIN BEARING SUPPORT OIL PAN ENGINE TO TRANSMISSION ADAPTER PLATE 2 Install engine tranmission in vehicle ENGINE 9 35 CYLINDER LINERS DESCRIPTION The cylinder wall liner used on this engine is of the wet design O rings are used to seal the liner to the engine block REMOVAL 1 Remove engine from vehicle 2 With engine completely disassembled use spe tool VM 1001 to remove liner assembly Fig 38 J9509 12 Fig 38 CYLINDER LINER REMOVER 9 36 ENGINE CYLINDER LINERS Continued 3 Tighten bolt on VM 1001 to remove liner from block Fig 39 80c6cac1 Fig 39 CYLINDER LINER REMOVAL 1 SPECIAL TOOL VM 1001 2 CYLINDER LINER 3 ENGINE BLOCK 4 Remove shims from cylinder liner or cylinder block recess Keep shims with each cylinder liner INSPECTION The cylinder walls should be checked for out of round and taper with a dial bore gauge The cylinder bore out of round is 0 100 mm 0039 in maximum and cylinder bore taper is 0 100 mm 0039 in max imum If the cylinder walls are badly scuffed or scored new liners should be installed and honed and new pistons and rings fitted Measure the cylinder bore at three levels in direc tions A and B Fig 40 Top
24. 19 Install engine cover Refer to 9 ENGINE INSTALLATION 20 Perform complete front wheel alignment Refer to 2 SUSPENSION WHEEL ALIGNMENT STANDARD PROCEDURE OIL PRESSURE RELIEF VALVE DESCRIPTION The oil pressure relief valve mounts in the front of the engine block and is used to control oil flow through the engines lubrication system Fig 61 0 cell 80 6 02 Fig 61 OIL PRESSURE RELIEF VALVE O RING OIL PRESSURE RELIEF VALVE CAP OIL PRESSURE RELIEF VALVE SPRING OIL PRESSURE RELIEF VALVE PLUNGER OND OIL PRESSURE RELIEF VALVE Continued REMOVAL 1 Remove engine oil pan Refer to 9 ENGINE LUBRICATION OIL PAN REMOVAL 2 Using special tool VM 1054 remove oil pres sure relief valve from engine block Fig 62 CA 80c6cb09 Fig 62 OIL PRESSURE RELIEF VALVE REMOVAL 1 VM 1054 2 OIL PRESSURE RELIEF VALVE 3 ENGINE BLOCK 4 OIL PUMP INSTALLATION 1 Thoroughly dean all components and relief valve pocket in cylinder block 2 Lubricate all oil pressure relief valve compo nents with engine oil 3 Install oil pressure relief valve plunger spring and cap 4 Using special tool VM 1059 push oil pressure relief valve cap in untill flush with engine block Fig 63 5 Install oil pan Refer to 9 ENGINE LUBRI CATION OIL PAN INSTALLATION 9 47 ENGINE G 28 A UG H 80c6cb13 Fig 63
25. 6 5 Connect fuel pressure sensor electrical connec tor Fig 6 6 Install engine cover and bracket assembly Refer to 9 ENGINE COVER INSTALLATION 7 Connect negative battery cable FUEL LINES DESCRIPTION DESCRIPTION All fuel lines up to the fuel injection pump are con sidered low pressure This includes the fuel lines from the fuel tank to the fuel injection pump The fuel return lines and the fuel drain lines are also considered low pressure lines High pressure lines are used between the fuel injection pump and the fuel injectors Refer to 14 FUEL SYSTEM WARN ING Also refer to High Pressure Fuel Lines Description Operation Refer to 14 FUEL SYSTEM FUEL DELIVERY FUEL LINES OPERATION KJ FUEL LINES Continued DESCRIPTION HIGH PRESSURE FUEL LINES NOTE High Pressure Fuel Lines Must Be Replaced At Each Disassembly Refer to 14 FUEL SYSTEM WARNING The high pressure fuel lines are used between the fuel injection pump and the fuel injector rail and between the fuel injection rail and fuel injectors All other fuel lines are considered low pressure lines OPERATION HIGH PRESSURE FUEL LINES WARNING HIGH PRESSURE LINES DELIVER DIE SEL FUEL UNDER EXTREME PRESSURE FROM THE INJECTION PUMP TO THE FUEL INJECTORS THIS MAY BE AS HIGH AS 1600BAR 23 200 PSI USE EXTREME CAUTION WHEN INSPECTING FOR HIGH PRESSURE FUEL LEAKS FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE SKIN CAUSING
26. 6 UD BALANCE PISTON 7 SNAP RING 8 UD PISTON 9 SPRING 10 DISC 11 UD CLUTCH 12 PLATE 13 CLUTCH RETAINER 14 SEAL 15 OD REV PISTON 16 BELLEVILLE SPRING 17 SNAP RING 18 SEAL RINGS 19 INPUT SHAFT 20 LUBRICATION CHECK VALVE AND SNAP RING INPUT CLUTCH ASSEMBLY Continued 7 Install Piston Guides 8504 into the input clutch retainer Fig 14 and onto the input clutch hub to guide the inner and outer underdrive piston seals into position 80 07427 Fig 14 Install Underdrive Piston Using 8504 1 TOOL 8504 8 Install the underdrive piston into the input clutch retainer and over the input clutch hub Fig 13 9 Install the UD OD balance piston return spring pack into the input clutch retainer 10 Install Piston Guide 8252 into the input clutch retainer Fig 15 to guide the UD OD balance piston seal into position inside the underdrive piston 80 07428 Fig 15 Install Balance Piston Using 8252 1 TOOL 8252 AUTOMATIC TRANSMISSION 545RFE 21 37 11 Install the UD OD balance piston into the input clutch retainer and the underdrive piston 12 Using Spring Compressor 8251 compress the UD OD return spring pack and secure the piston in place with the snap ring Fig 16 80 07426 Fig 16 Compressing UD OD Balance Piston Using Tool 8251 1 PRESS 2 TOOL 8251 3 BALANCE PISTON 13 Install the underdrive clutch pac
27. 8 3 Install engine cover and bracket assembly Refer to 9 ENGINE COVER INSTALLATION 4 Connect negative battery cable FUEL INJECTION 14 21 INTAKE AIR TEMPERATURE SENSOR DESCRIPTION The boost pressure intake air temperature sensor is mounted to the top of the intake manifold The sensor allows the ECM to monitor air pressure within the intake manifold This sensor is also used to monitor the intake air temperature Fig 9 09 8100 221 Fig 9 BOOST PRESSURE SENSOR INTAKE AIR TEMPERATURE SENSOR OPERATION The intake air temperature sensor is a negative temperature coefficient NTC thermistor resistance varies inversly with temperature This means at cold air temperature its resistance is high sothe volt age signal will be high As intake air temperature increases sensor resistance decreases and the signal voltage will be low This allows the sensor to provide an analog voltage signal 0 2 4 8 volts to the ECM REMOVAL 1 Refer to 14 FUEL SYSTEM FUEL INJ EC TION BOOST PRESSURE SENSOR REMOVAL INSTALLATION 1 Refer to 14 FUEL SYSTEM FUEL INJ EC TION BOOST PRESSURE SENSOR INSTALLA TION 14 22 FUEL INJECTION FUEL INJ ECTOR DESCRIPTION FUEL INJECTOR WARNING HIGH PRESSURE FUEL LINE DELIVER DIESEL FUEL UNDER EXTREME PRESSURE FROM THE INJECTION PUMP TO THE FUEL INJECTORS THIS MAY BE AS HIGH AS 1600BAR 23 200PSI USE EXTREME CAUTION WHEN INSPECTING FOR HIGH
28. FUEL SYSTEM 2 5L 2 8L TURBO DIESEL DESCRIPTION DIESEL FUEL DELIVERY SYSTEM The fuel system on the 2 5L 2 8L Common Rail Diesel Engine uses a fuel injection pump and an Electronic Control Module ECM The fuel delivery system consists of the e Accelerator pedal e Air cleaner housing element Fuel filter water separator Fuel heater Fuel heater relay Fuel injection pump Fuel injectors Fuel tank Fuel tank filler vent tube assembly Fuel tank filler tube cap Fuel tank module containing the rollover valve a fuel gauge sending unit fuel level sensor Fuel tubes lines hoses High pressure fuel injector lines Low pressure fuel supply lines Low pressure fuel return line Overflow valve Quick connect fittings Water draining WARNING HIGH FUEL SYSTEM PRESSURE WARNING HIGH PRESSURE FUEL LINES DELIVER FUEL UNDER EXTREME PRESSURE FROM THE INJECTION PUMP TO THE INJECTORS THIS MAYBE AS HIGH AS 1600BAR 23 200PSI USE EXTREME CAUTION WHEN INSPECTING FOR HIGH PRESSURE FUEL LEAKS FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE SKIN 0 FUEL SYSTEM 14 1 page STANDARD PROCEDURE STANDARD PROCEDURE PRIMING FUEL SYSTEM 2 STANDARD PROCEDURES CLEANING FUEL SYSTEM COMPONENTS 2 SPECIFICATIONS TORQUE 3 FUEL DELIVERY 4 FUEL INJECTION 18 CAUSING PERSONAL INJURY OR DEATH INSPECT HIGH PRESSURE FU
29. KJ 80cdb922 Fig 5 CHARGE AIR COOLER INLET HOSE CHARGE AIR COOLER 1 1 REAR FLOOR PAN HEAT SHIELD 2 HOSE CLAMP 2 HEAT SHIELD RETAINING NUTS 3 CHARGE AIR COOLER INLET HOSE 3 FRONT FLOOR PAN HEAT SHIELD 4 HOSE CLAMP CHARGE AIR COOLER AND INSTALLATION PLUMBING REMOVAL REMOVAL CAC INLET HOSE 1 Open and support hood of vehicle 2 Loosen hose clamps at both ends of charge air cooler CAC inlet hose Fig 5 3 Remove CAC inlet hose from turbocharger and CAC REMOVAL CAC OUTLET HOSE 1 Raise and support hood on vehicle 2 Loosen hose clamps at both ends of charge air cooler CAC outlet hose Fig 6 3 Remove hose from CAC and intake manifold inlet Fig 6 INSTALLATION CAC INLET HOSE 1 Install charge air cooler CAC inlet hose on turbocharger and CAC Fig 5 2 Tighten hose clamps Fig 5 3 Close hood INSTALLATION CAC OUTLET HOSE 1 Install charge air cooler CAC outlet hose on CAC and intake manifold inlet 2 Tighten both hose clamp on CAC outlet hose Fig 6 EXHAUST SYSTEM AND TURBOCHARGER 11 5 CHARGE AIR COOLER AND PLUMBING Continued 5 Fig 6 CHARGE AIR COOLER OUTLET HOSE CHARGE AIR COOLER HOSE CLAMP INTAKE MANIFOLD INLET HOSE CLAMP CHARGE AIR COOLER OUTLET HOSE 80cdb957 AON 3 Close hood TURBOCHARGER DESCRIPTION CAUTION The turbocharger is a performance part and must
30. STRUCTURAL SUPPORT 3 OIL PAN 4 STRUCTURAL SUPPORT TO TRANSMISSION ADAPTER PLATE RETAINING BOLT 5 OIL PRESSURE SWITCH 6 OIL PRESSURE SWITCH ADAPTER 7 OIL PRESSURE RELIEF VALVE PLUNGER 8 OIL PRESSURE RELIEF VALVE SPRING 9 O RING 10 OIL PRESSURE RELIEF VALVE CAP 11 OIL PAN GASKET 12 OIL PAN RETAINING BOLTS 7 Torque the steering gear mounting bolts to 162N m 120 Ibs ft 8 Remove the cradle support devise and lower the vehicle 9 Lower the engine using support fixture special tool 8534 until the engine mount through bolts are seated the cradle 10 Raise the vehicle 11 Torque engine mount through bolts to 88N m 65 Ibs ft 12 Install front axle assembly Refer to 3 DIF FERENTIAL amp DRIVELINE FRONT AXLE INSTALLATION KJ 13 Install front axle skid plate if equipped Refer to 13 FRAME amp BUMPERS FRAME FRONT SKID PLATE INSTALLATION 14 Install both front wheel and tire assemblies Refer to 22 TIRESAWWHEELS AWHEELS STAN DARD PROCEDURE tighten to 115 155 85 115 Ibs ft NOTE When removing engine support fixture care must be taken not to damage the hood ajar switch mounted to the right inner fender well if equipped 15 Lower the vehicle and remove the engine sup port fixture 16 Refill engine to proper level with the correct viscosity engine oil 17 Connect negative battery cable 18 Start engine and inspect for leaks
31. switches is to help the TCM detect when clutch cir cuit hydraulic failures occur The switches close at 23 psi and open at 11 psi and simply indicate whether or not pressure exists The switches are continuously monitored by the TCM for the correct states open or closed in each gear as shown in the following chart GEAR L R 2 4 UD OD R OP OP OP OP OP P N CL OP OP OP OP 1ST CL OP OP CL OP 2ND OP CL OP CL OP 2ND PRIME OP OP CL CL OP D OP OP OP CL CL 4TH OP OP CL OP CL 5TH OP CL OP OP CL L R is closed if output speed is below 100 rpm in Drive and Manual 2 L R is open in Manual 1 A Diagnostic Trouble Code DTC will set if the TCM senses any switch open or closed at the wrong time in a given gear REMOVAL 1 Remove the valve body from the transmission Fig 25 Fig 25 Valve Body Bolts 1 VALVE BODY TO CASE BOLT 6 2 Remove the screws holding the transmission solenoid TRS assembly onto the valve body Fig 26 3 Separate the transmission solenoid TRS assem bly from the valve body Q A k 9 29 8 S 5 5 80607445 Fig 26 Transmission Solenoid TRS Assembly Screws 1 SOLENOID PACK BOLTS 15 INSTALLATION 1 Place TRS selector plate in the PARK position
32. tings 8 Disconnect fuel tank module electrical connec tor 9 Remove module lockring using a brass drift and a hammer counter clockwise 10 Carefully lift upper section of fuel tank mod ule from fuel tank exposing connections Fig 15 lift upper section from tank slowly until rubber gasket can be retained If not the gasket will fall into fuel tank 11 Disconnect electrical connector at bottom of upper tank module section Fig 15 12 Disconnect both fuel lines at bottom of upper tank module section Fig 15 13 Remove upper section of fuel tank module 14 Using an approved gas holding tank drain fuel tank through tank module opening If only FUEL DELIVERY 14 13 80 8839 Fig 14 ACCESS PLATE FLOORPAN AT REAR FUEL PUMP MODULE ACCESS PLATE NUTS 4 OPENING TO PUMP MODULE gt gt mmm TU 80cf00c1 Fig 15 FUEL TANK MODULE 1 FUEL TANK CHECK CONTROL VALVE 2 QUICK CONNECT FITTINGS 3 ELECTRICAL CONNECTOR 14 14 FUEL DELIVERY FUEL TANK MODULE Continued upper section of tank module is being serviced draining fuel tank is not necessary If any other fuel tank component is being serviced the tank must be completely drained 15 To remove lower section of tank module a Using finger pressure push on elastic release tab while sliding lock tab upward Fig 16 b The sides of lower t
33. 16 Install engine cover Refer to 9 ENGINE COVER INSTALLATION 17 refill cooling system Refer to 7 COOLING ENGINE STANDARD PROCEDURE 18 Connect negative battery cable KJ WATER PUMP DESCRIPTION The water pump on the 2 5L 2 8L CRD diesel has a die cast aluminum housing It bolts to a aluminum housing which attaches to the engine block OPERATION The water pump is used to circulate coolant through the cooling system The coolant is pumped through the engine block cylinder head heater core EGR cooler viscous heater and radiator REMOVAL WATER PUMP 1 Disconnect negative battery cable 2 Drain cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 3 Remove timing belt inner and outer covers Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 4 Remove water pump retaining bolts and pump Fig 11 80 40647 Fig 11 WATER PUMP LOCATION CYLINDER HEAD ENGINE BLOCK OIL COOLER OIL FILTER HOUSING WATER PUMP CLEANING Clean gasket mating surfaces as necessary KJ WATER PUMP Continued INSTALLATION 1 Clean mating surfaces of water pump housing and engine block as necessary 2 Place new oring in groove in water pump housing Install water pump and retaining bolts Torque bolts to 24 4N m 3 Install both inner and outer timing belt covers Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S IN
34. 4 Using the ARROW key select in or out of vehi de testing and press ENTER to make a selection 5 If not selected choose the Cold Cranking Amp CCA battery rating Or select the appropriate bat tery rating for your area see menu The tester will then run its self programmed test of the battery and display the results Refer to the test result table noted below CAUTION If REPLACE BATTERY is the result of the test this may mean a poor connection between the vehicle s cables and battery exists After discon necting the vehicle s battery cables from the bat tery retest the battery using the OUT OF VEHICLE test before replacing 6 While viewing the battery test result press the CODE button and the tester will prompt you for the last 4 digits of the VIN Use the UP DOWN arrow buttons to scroll to the correct character then press ENTER to select and move to the next digit Then press the ENTER button to view the SERVICE CODE Pressing the CODE button a second time will return you to the test results BATTERY TEST RESULTS GOOD BATTERY GOOD RECHARGE Fully charge battery and return to service CHARGE amp RETEST Fully charge battery and retest battery REPLACE BATTERY Replace the battery and retest complete system BAD CELL REPLACE Replace the battery and retest complete system NOTE The SERVICE CODE is required on every warranty claim submitted for battery replacement KJ IGNITION CONTROL TABLE OF CONTENTS
35. 54 668 14 HALHSANOO 09 ee HOLNTO 12 4 pRLA dO OH On Puz oZ MOT u1 8 0 TN 37 5 d 2 c L 8 H3AO 45 1 Y AUTOMATIC TRANSMISSION 545RFE AUTOMATIC TRANSMISSION 545RFE Continued 21 8 59100808 3SH3A3H MO TH JHO 99 32 0 811 09 095 67 et morer 4004865 14 1 0419 313 HOSN3S S3Hd SNIT Sd1 105 S3Hd SOd ovi 10373S ILINW SW HOLIMS S3Hd7Sd SHNSSAYd 1d H31H3ANOO 00 COOLER HOLD asuaAdu ou 2 21 9 AUTOMATIC TRANSMISSION 545RFE AUTOMATIC TRANSMISSION 545RFE Continued MIOTE 3SH3A3H NI DTINVYCAH 9900808 59 443099 sd saunssaua 92 96 8 1 09 092 9 SD 2 2 221222112121111 11 112 LAITIITI ld INJA A
36. AUTOMATIC TRANSMISSION 545RFE Continued NOTE The 545RFE utilizes closed loop control of pump line pressure The pressure readings may therefore vary greatly but should always follow line pressure Some common pressures that can be measured to evaluate pump and dutch performance are the upshift downshift pressures and the garage shift pressures The upshift downshift pressure for all shifts except the 4 5 shift is 120 psi The upshift pressure for the 4 5 shift is 130 psi The garage shift pressure when performing a N R shift is 220 psi The T 2 Y garage shift pressure for the R N and N 1 shifts is rls 120 psi 2 9 55 Y x ME SO 80c07 2fa Fig 5 Valve Body Pressure Tap Adapter 8258 A 1 545RFE TRANSMISSION 2 TOOL 8258 A TEST PROCEDURE pressure readings should be taken with the transmission fluid level full transmission oil at the normal operating temperature and the engine at 1500 rpm Check the transmission for proper opera tion in each gear position that is in question or if a specific element is in question check the pressure readings in at least two gear positions that employ that element Refer to the Hydraulic Schematics at the rear of this section to determine the correct pres sures for each element in a given gear position KJ AUTOMATIC TRANSMISSION 545RFE AUTOMATIC TRANSMISSION 545RFE Continued 21 6
37. Bearing Ena Pay Thrust Washers Available 27 670 27 820 mm Carrier with thrust washers installed 9 7 ENGINE 2 5L 2 8L TURBO DIESEL Continued DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION MAIN BEARING CARRIERS PISTON PINS Internal Diameter Type Full Floating Front 67 025 67 050 mm 31 990 31 996 mm Center 66 670 66 690 mm 32 000 32 004 Rear 85 985 86 005 mm 0 010 0 020 mm gt 0 004 0 012 PISTON RINGS Internal Diameter 93 997 94 015 mm 0 00 0 05 mm Adjustment Oil Control 0 035 0 080 mm 0300501 CYLINDER HEAD Oil Control 0 25 0 50 9495 9505 mm 2 Journal Diameter Front 29 960 29 980 mm Gasket Thickness 1 32 mm 0 08 0 notches Be tee 39 250 39 270 mm 1 52 mm 0 08 2 0 03 0 08 mm notches 39 250 39 270 mm 05008 mm Small End Bearing 32 035 32 050 mm HYDRAULIC LIFTER Internal Diameter Outside Diameter 11 994 0 006 mm Large End Internal 53 977 54 016 mm VALVES Diameter Intake Valve PISTONS Skit Diameter 15 6 2 A T D C i iameter measure 912 93 mm 2 2 1 0 644 27 802 above the bottom of the Exhaust Valve Piston Clearance 0 010 0 022 mm 32 2 A T D C Top of Piston to Cylinder 0 69 0 83 mm Face Angle inm 4572555738 Piston Potrusion 0 49 0 60 Fit Gasket Exas 45 25 45 35 Number 1 32 0 notches Head Diameter or holes 32 30 32 80 m
38. COOLANT CAN OCCUR 2 Remove pressure vent cap when engine is cold idle engine until thermostat opens you should observe coolant flow while looking down in the cool ant recovery pressure container Once flow is detected install the pressure vent cap DIAGNOSIS AND TESTING COOLING SYSTEM AERATION Low coolant level in a cross flow radiator will equalize in both tanks with engine off With engine at running and at operating temperature the high pressure inlet tank runs full and the low pressure outlet tank drops resulting in cooling system aera tion Aeration will draw air into the water pump resulting in the following e High reading shown on the temperature gauge e Loss of coolant flow through the heater core e Corrosion in the cooling system 7 2 COOLING 2 5L 2 8L TURBO DIESEL KJ COOLING 2 5L 2 8L TURBO DIESEL Continued e Water pump seal may run dry increasing the risk of premature seal failure e Combustion gas leaks into the coolant can also cause aeration DIAGNOSIS AND TESTING COOLING SYSTEM LEAK TEST WARNING THE WARNING WORDS DO NOT OPEN HOT ON THE RADIATOR PRESSURE CAP IS A SAFETY PRECAUTION WHEN HOT PRESSURE BUILDS UP IN COOLING SYSTEM TO PREVENT SCALDING OR INJURY THE RADIATOR CAP SHOULD NOT BE REMOVED WHILE THE SYSTEM IS HOT OR UNDER PRESSURE With engine not running remove pressure vent cap from the coolant recovery pressure container and wipe the filler neck sealing seat cl
39. COVER REMOVAL 3 Disconnect heater core supply line at heater core and viscous heater Fig 3 Remove hose from vehicle 4 Disconnect heater core return line from heater core and EGR cooler Fig 3 Remove hose from vehi cle AUN KJ COOLANT SYSTEM HOSES Continued 1 p Oat WES 22 res gt MC PACER Fig 3 HEATER CORE COOLANT HOSES HEATER CORE TO VISCOUS HEATER HOSE MOUNTING STUD HOSE CLAMP HOSE CLAMP HEATER CORE TO EGR COOLER HOSE AUN INSTALLATION INSTALLATION UPPER RADIATOR HOSE 1 Install upper radiator hose on radiator and thermostat housing Fig 2 2 Reposition hose clamps in proper position 3 Refill cooling system to proper level Refer to 7 COOLING ENGINE COOLANT STANDARD PRO CEDURE INSTALLATION HEATER CORE HOSES 1 Connect heater core supply hose to heater core and viscous heater Position hose clamps into proper position 2 Connect heater core return hose to heater core and EGR cooler Position hose clamps into proper position 3 Install engine cover to engine Refer to 9 ENGINE COVER INSTALLATION 4 Refill cooling system to proper level Refer to 7 COOLING ENGINE COOLANT STANDARD PRO CEDURE ENGINE 7 19 ENGINE COOLANT TEMP SENSOR DESCRIPTION The engine coolant temperature sensor threads into a coolant passage in the cylinder head Fig 4 New sensors hav
40. ECM electrical connectors Fig 2 5 Connect negative battery cable 80cc7aa6 Fig 2 ENGINE CONTROL MODULE ECM REMOVAL INSTALL ECM ELECTRICAL CONNECTORS ENGINE CONTROL MODULE ECM ECM MOUNTING BRACKET ECM MOUNTING BRACKET MOUNTING STUDS MOUNTING BRACKET RETAINING NUTS KJ ENGINE SYSTEMS 8 1 ENGINE SYSTEMS TABLE OF CONTENTS page BATTERY DESCRIPTION OPERATION DIAGNOSIS AND TESTING BATTERY STANDARD PROCEDURE STANDARD PROCEDURE SPIRAL PLATE BATTERY 2 BATTERY DESCRIPTION Vehicles equipped with a diesel engine utilize a spi ral wound plate designed battery with recombination technology This is a maintenance free battery that is capable of delivering more power than a conventional battery This additional power is required by a diesel engine during cold cranking Spiral plate technology takes the elements of tradi tional batteries lead and sulfuric acid to the next level By tightly winding layers of spiral grids and acid permeated vitreous separators into cells the manufacturer has developed a battery with more power and service life than conventional batteries the same size The spiral plate battery is completely per manently sealed Through gas recombination hydro gen and oxygen within the battery are captured during normal charging and reunited to form the water within the electrolyte eliminating the need to add dis
41. ENGINE J TEC diesel only MIS CELLANEOUS and SRI MEMORY CHECK 8 The DRB 1119 will ask Is odometer reading between XX and XX Select the YES or NO button on the DRB III If NO is selected the DRB 1119 will read Enter odometer Reading F rom I P odometer gt Enter the odometer reading from the Instrument Panel and press ENTER PROGRAMMING THE SKIM 1 Turn the ignition switch on transmission in park neutral 2 Use the DRB 1119 and select THEFT ALARM SKIM then MISCELLANEOUS 3 Select PCM REPLACED GAS ENGINE 4 Program the vehicle four digit PIN into SKIM 5 Select COUNTRY CODE and enter the correct country NOTE Be sure to enter the correct country code If the incorrect country code is programmed into SKIM the SKIM must be replaced 6 Select YES to update VIN the SKIM will learn the VIN from the PCM 7 Press ENTER to transfer the secret key the PCM will send the secret key to the SKIM 8 Program ignition keys to SKIM NOTE If the PCM and the SKIM are replaced at the same time all vehicle keys will need to be replaced and programmed to the new SKIM PROGRAMMING IGNITION KEYS TO THE SKIM 1 Turn the ignition switch on transmission in park neutral 2 Use the DRB 1119 and select THEFT ALARM SKIM then MISCELLANEOUS 3 Select PROGRAM IGNITION KEY S 4 Enter secured access mode by entering the vehicle four digit PIN NOTE A maximum of eight keys can be learned to each S
42. Incorrect belt tension 2 Belt contacting stationary object 1 Correct rubbing condition 2 Replace belt 3 Replace belt 1 Inspect Replace tensioner if necessary 2 Replace belt 3 Replace pulley 4 Replace belt tensile member and rubber matrix REMOVAL NOTE The belt routing schematics are published from the latest information available at the time of publication If anything differs between these sche matics and the Belt Routing Label use the sche matics on Belt Routing Label This label is located in the engine compartment CAUTION DO NOT LET TENSIONER ARM SNAP BACK TO THE FREEARM POSITION SEVERE DAM AGE MAY OCCUR TO THE TENSIONER Belt tension is not adjustable Belt adjustment is maintained by an automatic spring loaded belt ten sioner 1 Disconnect negative battery cable 2 Rotate belt tensioner until it contacts its stop Remove belt then slowly rotate the tensioner into the freearm position INSTALLATION NOTE The belt routing schematics are published from the latest information available at the time of publication If anything differs between these sche matics and the Belt Routing Label use the sche matics on Belt Routing Label This label is located in the engine compartment Belt tension is not adjustable Belt adjustment is maintained by an automatic spring load belt ten sioner 1 Check condition of all pulleys CAUTION When installing the serpentine accessory dri
43. LOCKING TOOL VM 1066 VALVE COVER ALIGNMENT PINS 9 14 ENGINE ENGINE 2 5L 2 8L TURBO DIESEL Continued c cm 1 1 80c172d1 VM 1072 COMPRESSION TESTER ADAPTER 80c17b55 VM 1075 FLYWHEEL ALIGNMENT PINS 80c17883 VM 8872 TDC LOCATING PIN VM 1073 CRANKSHAFT FRONT BEARING VM 8873 90 DEGREES AFTER TDC LOCATING PIN 80 1727 VM 1074 TIMING BELT RETAINER KJ CYLINDER HEAD STANDARD PROCEDURE STANDARD PROCEDURE VALVE SERVICE This procedure is done with the engine cylinder head removed from the block DISASSEMBLY 1 Remove the engine cylinder head from the inder block Refer to cylinder head removal and installation in this section 2 Use Valve Spring Compressor Tool and com press each valve spring 3 Remove the valve locks retainers and springs 4 Use a smooth stone or a jewelers file to remove any burrs on the top of the valve stem especially around the groove for the locks 5 Remove the valves and place them in a rack in the same order as removed VALVE CLEANING 1 Clean all carbon deposits from the combustion chambers valve ports valve stems valve stem guides and head 2 Clean all grime and gasket material from the engine cylinder head machined gasket surface INSPECTION 1 Inspect for cracks in the combustion chambers and valve ports 2 Inspect for cracks on the exhaust seat 3 Inspect for cracks in the gasket surface
44. PRESSURE FUEL LEAKS FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE SKIN CAUSING PERSONAL INJURY OR DEATH INSPECT FOR HIGH PRESSURE LEAKS WITH A SHEET OF CARDBOARD WEAR SAFETY GOG GLES AND ADEQUATE PROTECTIVE CLOTHING WHEN SERVICING FUEL SYSTEM Refer to 14 FUEL SYSTEM WARNING There are individual fuel injectors for all four cylinders These fuel injectors are used to spray fuel into the combustion chamber Fig 10 Kos 80b4da8e Fig 10 FUEL INJECTOR FUEL INJECTOR NOZZLE FUEL INLET FITTING ELECTRICAL CONNECTION OPERATION Refer to 14 FUEL SYSTEM WARNING The injector operation can be subdivided into four operat ing states with the engine running and the high pressure pump generating pressure KJ Injector closed with high pressure applied Injector opens start of injection Injector opened fully Injector closes end of injection 80b52382 Fig 11 INJECTOR COMPONENTS INJECTOR CLOSED AT REST STATUS ELECTRICAL CONNECTION TRIGGERING ELEMENT SOLENOID VALVE FUEL INLET HIGH PRESSURE FROM THE RAIL VALVE BALL BLEED ORIFICE FEED ORIFICE VALVE CONTROL CHAMBER VALVE CONTROL PLUNGER 10 FEED PASSAGE TO THE NOZZLE 11 NOZZLE NEEDLE Injector closed with high pressure applied With the injector closed at rest state the solenoid valve is not energized and is therefore closed With the
45. REMOVAL AND INSTALLATION FUEL FILTER WATER SEPARATOR BRACKET BRACKET RETAINING NUTS FUEL FILTER WATER SEPARATOR RETAINING NUTS FUEL FILTER WATER SEPARATOR WATER DRAIN 14 6 FUEL DELIVERY WATER IN FUEL SENSOR DESCRIPTION The WIF sensor is located in the bowl assembly of the fuel filter water separator Fig 4 80ceddce Fig 4 FUEL FILTER WATER SEPARATOR 1 FUEL FILTER WATER SEPARATOR ASSEMBLY 2 WATER IN FUEL SENSOR 3 FUEL HEATER OPERATION The sensor sends an input to the Engine Control Module ECM when it senses water in the fuel filter water separator As the water level in the filter sep arator increases the resistance across the WIF sensor decreases This decrease in resistance is sent as a signal to the ECM and compared to a high water standard value Once the value reaches 30 to 40 kilohms the ECM will activate the water in fuel warning lamp This all takes place when the ignition key is initially put in the ON position REMOVAL 1 Disconnect negative battery cable 2 Drain fuel filter water separator assembly by loosening drain at bottom of fuel filter cap 3 Disconnect WIF sensor electrical Fig 4 connector KJ 4 Unscrew WIF sensor from fuel filter cap at bot tom fuel filter water separator assembly INSTALLATION 1 Install WIF sensor into fuel filter cap hand tight 2 Connect WIF sensor electrical connector Fig 4 3 Prime fuel s
46. Remove cooling fan and fan drive viscous dutch assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 4 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 5 Remove cooling fan support Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL 6 Remove vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER REMOVAL KJ ENGINE 9 53 TIMING BELT CHAIN COVER S Continued 7 Remove timing belt outer cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 8 Remove timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL 9 Remove timing belt idler pulleys Refer to 9 ENGINE VALVE TIMING TIMING BELT IDLER PULLEY REMOVAL 10 Using special tool VM 1055 remove camshaft sprockets Fig 72 Q RDE Jp 80c5f3ef Fig 72 CAMSHAFT SPROCKET REMOVAL INSTALLATION TIMING BELT INNER COVER CAMSHAFT SPROCKET IDLER PULLEYS CAMSHAFT SPROCKET 1055 11 Remove timing belt tensioner Refer to 9 TIMING TMNG BELT CHAIN TENSIONER amp PULLEY REMOVAL 12 Remove injection pump sprocket Refer to 14 FUEL SYSTEM FUEL DELIVERY FUEL INJEC TION PUMP REMOVAL 13 Remove timing belt inner cover retaining bolts and remove cover Fig 73 REMOVAL TIMING BELT OUTER COVER 1 Disconnect negative batt
47. SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS 20 0208 TWYLNAN MYVd NI NOOO 33095 ANA dwns 0081 1v 2 SGION310 ERER er A p A Wu 22 22 TTT 212 ao LE VS 4 ba A IIIIIII E RS SSS BLLELELLLLILIIII INJA A MO IH3AO Q3JIVA3T37 HOSN3S Saud SNIT Sd1 7108 TOHLNOO S3tid SOd 2 LO3TaS LINW SW HO LIMS S3Hd Sd 14 563 14 HALYIANOO 99 HOLNTO 10 3AIHQH3AO QO H LNTO Puz oz 5 2 21 7 AUTOMATIC TRANSMISSION 545RFE AUTOMATIC TRANSMISSION 545RFE Continued 8 H3AO 75120808 0081 NO 99 340 99 an sw 99711 sa saunssaua 08 61 8 1 66 soi se_ 22225222 uaria E Nana i 4 5 26696665 H H ld IN3A A 041 313 HOSN3S 68 3NI1 Sd1 10S S3Hd SOd ov 10373S ILINW SW HOLIMS 53 4
48. THROUGH THE OVERFLOW TUBE AND WHEN THE SYSTEM STOPS PUSHING COOLANT AND STEAM INTO THE CRS TANK AND PRESSURE DROPS PUSH DOWN AND REMOVE THE CAP COM PLETELY SQUEEZING THE RADIATOR INLET HOSE WITH A SHOP TOWEL TO CHECK PRESSURE BEFORE AND AFTER TURNING TO THE FIRST STOP IS RECOMMENDED CLEANING Use only a mild soap to clean the pressure cap INSPECTION Hold the cap in your hand top side up Fig 14 The vent valve at the bottom of the cap should open If the rubber gasket has swollen preventing the valve from opening replace the cap Hold the cleaned cap in your hand upside down If any light can be seen between vent valve and the rubber gasket replace the cap Do not use a replacement cap that has a spring to hold the vent shut A replacement cap must be of the type designed for coolant reserve systems This design ensures coolant return to the radiator HOSE CLAMPS DESCRIPTION HOSE CLAMPS The cooling system utilizes spring type hose clamps If a spring type clamp replacement is neces sary replace with the original Mopar equipment spring type clamp WARNING CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES WHEN REMOVING OR INSTALLING USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP SUCH AS SPECIAL CLAMP TOOL NUMBER 6094 Fig 15 SNAP ON CLAMP TOOL NUMBER HPC 20 MAY BE USED FOR LARGER CLAMPS ALWAYS WEAR SAFETY GLASSES WHEN SERVIC ING CONSTANT TENSION CLAMPS
49. The ECM uses inputs from the sensor and solenoid to calculate and determine if a high fuel pressure problem exists Fuel Injector Malfunctions The ECM can deter mine if a fuel injector has an electrical problem The fuel injectors on the diesel engine are controlled by the ECM ECM NON MONITORED SYSTEMS The ECM does not monitor the following circuits systems or conditions that could have malfunctions that result in driveability problems A DTC will not be displayed for these conditions Cylinder Compression The ECM cannot detect uneven low or high engine cylinder compression Exhaust System The ECM cannot detect a plugged restricted or leaking exhaust system Vacuum Assist Leaks or restrictions in the vac uum circuits of the Exhaust Gas Recirculation Sys tem EGR are not monitored by the ECM ECM System Ground The ECM cannot deter mine a poor system ground However a DTC may be generated as a result of this condition ECM PCM Connector Engagement The ECM cannot determine spread or damaged connector pins However a DTC may be generated as a result of this condition HIGH AND LOW LIMITS The ECM compares input signals from each input device There are high and low limits that are pro grammed into the ECM for that device If the inputs are not within specifications and other DTC criteria are met a DTC will be stored in memory Other DTC criteria might include engine rpm limits or input voltages from other sensors or
50. accelerator pedal position sensor assembly position sensor 80 140 Fig 3 ACCELERATOR PEDAL POSITION SENSOR ASSEMBLY 80c1d108 Fig 4 ACCELERATOR PEDAL POSITION SENSOR ASSEMBLY OPEN INSTALLATION 1 Connect accelerator cable to accelerator pedal position sensor assembly and close cover 2 Attach accelerator pedal position sensor assem bly to mounting bracket 3 Connect sensor electrical connector 4 Connect negative battery cable 14 20 FUEL INJECTION KJ ACCELERATOR PEDAL POSITION SENSOR Continued 80cda4cc Fig 5 ACCELERATOR PEDAL POSITION SENSOR 1 RETAINING BOLTS 2 ACCELERATOR CABLE 3 ACCELERATOR PEDAL POSITION SENSOR BRACKET 4 ACCELERATOR PEDAL POSITION SENSOR acon ERATUM PEDAL POSITION SENSOR ELECTRICAL 80c1d108 Fig 6 ACCELERATOR PEDAL POSITION SENSOR ASSEMBLY OPEN BOOST PRESSURE SENSOR DESCRIPTION The boost pressure intake air temperature sensor is mounted to the top of the intake manifold The sensor allows the ECM to monitor air pressure within the intake manifold This sensor is also used to monitor the intake air temperature Fig 7 09 8100 221 Fig 7 BOOST PRESSURE SENSOR INTAKE AIR TEMPERATURE SENSOR OPERATION When the intake manifold pressure is low sensor voltage output is 0 25 1 8 volts at the ECM When the intake manifold pressure is high due to turbo boost sensor voltage output is 2 0 4 7 volts The sen
51. be performed anytime a malfunction is observed or suspected Retain all receipts Replace if there is superficial wear bearing clear ance or evident grease leak 0 4 MAINTENANCE SCHEDULES KJ MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U S CANADA and MEXICO Continued Schedule A Change the engine oil and engine oil filter Inspect the ball joints Inspect the brake linings Inspect the engine air filter element Replace as necessary Replace the engine air filter element Inspect the engine accessory drive belt Replace the engine accessory drive Replace the fuel filter water separator unit Inspect idler pulleys and timing belt tensionert Replace the engine timing belt Inspect the transfer case fluid Change the engine oil and engine oil filter Inspect the ball joints Inspect the brake linings Inspect the engine accessory drive belt Inspect the engine air filter element Replace as necessary Replace the engine air filter element Replace the fuel filter water separator unit Flush and replace the engine coolant Inspect the transfer case fluid Drain and refill the transfer case fluid 20 000 km 40 000 km 60 000 km 80 000 km 100 000 km p nl pee i X 1 HN X X pu p E p qp x qp jJ 120 000 km 140 000 km 160 000 km 180 000 km X x X X X X X X X X X X X X Drai
52. bleed orifice closed the valve spring forces the FUEL ECTOR Continued armature s ball onto the bleed orifice seat The rail s high pressure build up in the valve control chamber and the same pressure is also present in the nozzle s chamber volume The rail pressure applied at the control plunger s end face together with the force of the nozzle spring maintain the nozzle in the dosed position against the opening forces applied to its pressure stage Fig 11 Injector opens start of injection The solenoid valve is energized with the pickup current which serves to ensure that it open quickly The force exerted by the triggered solenoid now exceeds that of the valve spring and the armature opens the bleed orifice Almost immediately the high level pick up current is reduced to the lower holding current required for the electromagnet This is possi ble due to the magnetic circuit s air gap now being smaller When the bleed orifice opens fuel can flow from the valve control chamber into the cavity situ ated above it and from there via the fuel return to the tank The bleed orifice prevents complete pres sure balance and the pressure in the valve control chamber sinks as a result This leads to the pressure in the valve control chamber being lower than that in the nozzles chamber volume which is still at the same pressure level as the rail The reduced pressure in the valve control chamber causes a reduction in the for
53. coating will result in excessive floor pan temperatures and objectionable fumes 11 2 EXHAUST SYSTEM AND TURBOCHARGER _ EXHAUST SYSTEM AND TURBOCHARGER Continued SPECIFICATIONS TORQUE 2 5L 2 8L DIESEL TORQUE SPECIFICATIONS DESCRIPTION Nm Fe bs Exhaust Manifold Heat 27 5 21 Shield Bolts Turbocharger Bracket 47 1 35 Bolts Turbocharger Downpipe 32 4 24 Nuts Turbocharger Oil Supply 24 5 18 215 Line Fitting Turbocharger Oil Return 10 8 Line bolts Turbocharger to Exhaust 32 4 24 Manifold Nuts EXHAUST PIPE REMOVAL 1 Raise vehicle on hoist 2 Remove exhaust pipe to muffler and tail pipe assembly retaining nuts 3 Remove exhaust pipe to turbocharger downpipe retaining bolts Fig 1 4 Using a suitable pry bar remove exhaust pipe from rubber exhaust hangers Fig 2 5 Lower exhaust pipe from vehicle INSTALLATION 1 Install exhaust pipe in vehicle and attach rub ber exhaust hangers to exhaust pipe Fig 2 2 Using a new gasket connect exhaust pipe to turbocharger downpipe Fig 1 Torque bolts to 32 4N m 3 Install exhaust pipe to muffler and tailpipe assembly retaining nuts Torque nuts to 32 4N m 4 Lower vehicle from hoist MUFFLER REMOVAL 1 Raise vehicle on hoist 2 Remove exhaust pipe to muffler and tailpipe assembly retaining nuts Fig 3 3 Using a suitable pry bar pry muffler
54. continu ing the charging operation Damage to the battery may result After the battery has been charged to 12 6 volts or greater perform a load test to determine the battery cranking capacity Refer to Battery Diagnosis and Testing for the proper battery test procedures If the battery will endure a load test return the battery to service If the battery will not pass a load test it is faulty and must be replaced Clean and inspect the battery hold downs tray terminals posts and top before completing battery service Refer to Battery System Cleaning for the proper battery system cleaning procedures and Bat tery System Inspection for the proper battery system inspection procedures BATTERY Continued CHARGING A COMPLETELY DISCHARGED BATTERY SPIRAL PLATE BATTERY The following procedure should be used to recharge a completely discharged battery Unless this proce dure is properly followed a good battery may be needlessly replaced 1 Measure the voltage at the battery posts with a voltmeter accurate to 1 10 0 10 volt Fig 1 Refer to Battery Removal and Installation for access instructions If the reading is below ten volts the battery charging current will be low It could take several hours before the battery accepts a current greater than a few milliamperes Such low current may not be detectable on the ammeters built into many battery chargers 898A 12 Fig 1 Voltmeter Accurate to 1 10 Volt Con
55. controlled by two glow plug relays Each glow plug relay con trols two glow plugs Refer to glow plug relays for more information REMOVAL 1 Disconnect negative battery cable 2 Remove generator Refer to 8 ELECTRICAL CHARGING GENERATOR REMOVAL 3 Disconnect glow plug electrical connectors Fig 6 NOTE The intake manifold inlet tube must be removed to remove the cylinder 3 glow plug Fig 5 KJ CONTROL 81 3 GLOW PLUG Continued 2 dA oe 80439614 Fig 5 INTAKE MANIFOLD AIR INLET TUBE CYLINDER HEAD COVER INTAKE MANIFOLD AIR INLET TUBE GASKET INTAKE MANIFOLD AIR INLET TUBE RETAINING BOLTS 804368 5 4 Remove glow plugs from cylinder head Fig 6 INSTALLATION 1 Install glow plugs into cylinder head Fig 6 2 Connect glow plug electrical connectors Fig 6 3 Install intake manifold air inlet tube Fig 5 4 Install generator Refer to 8 ELECTRICAL CHARGING GENERATOR INSTALLATION 5 Connect negative battery cable Fig 6 CYLINDER HEAD ASSEMBLY CYLINDER HEAD BOLT GLOW PLUG COOLANT TEMPERATURE SENSOR CYLINDER HEAD ALIGNMENT DOWEL GLOW PLUG HARNESS CYLINDER LINER CYLINDER BLOCK CYLINDER HEAD GASKET CYLINDER HEAD 0 ROCKER ARM ASSEMBLIES 81 4 IGNITION CONTROL GLOW PLUG RELAY DESCRIPTION There are two glow p
56. diagnostics Certain cri teria must be met for a diagnostic trouble code to be entered into the ECM memory The criteria may be a range of engine rpm engine temperature time or other input signals to the ECM If all of the criteria for monitoring a system or circuit are met and a problem is sensed then a DTC will be stored in the ECM memory It is possible that a DTC for a moni tored circuit may not be entered into the ECM mem ory even though a malfunction has occurred This may happen when the monitoring criteria have not been met The ECM compares input signal voltages from each input device with specifications the estab lished high and low limits of the input range that are programmed into it for that device If the input voltage is not within the specifications and other trouble code criteria are met a DTC will be stored in the ECM memory ECM OPERATING MODES As input signals to the ECM change the ECM adjusts its response to the output devices For exam ple the ECM must calculate a different fuel quantity and fuel timing for engine idle condition than it would for a wide open throttle condition There are several different modes of operation that determine how the ECM responds to the various input signals Ignition Switch On Engine Off When the ignition is turned on the ECM activates the glow plug relay for a time period that is deter mined by engine coolant temperature atmospheric temperature and battery voltage
57. fuel rail is common to all cylinders hence it s name common rail Even when large quantities of FUEL RAIL Continued FUEL DELIVERY 14 7 8105dece Fig 5 FUEL SYSTEM COMPONENTS FUEL INJECTOR RETURN LINE WASHER FUEL INJECTOR INJECTOR ASSEMBLY LUBRACATION POINT HIGH PRESSURE FUEL LINE FUEL RAIL 7 FUEL RAIL PRESSURE SENSOR 8 HIGH PRESSURE FUEL RAIL SUPPLY LINE 9 INJECTION PUMP HIGH PRESSURE OUTLET 10 FUEL PRESSURE SOLENOID 11 FUEL PRESSURE RETURN INLET fuel are extracted the fuel rail maintains a constant inner pressure This ensures that the injection pres sure remains constant from the moment the injector opens REMOVAL WARNING HIGH PRESSURE LINES DELIVER DIE SEL FUEL UNDER EXTREME PRESSURE FROM THE INJECTION PUMP TO THE FUEL INJECTORS THIS MAY BE AS HIGH AS 1600BAR 23 200 PSI USE EXTREME CAUTION WHEN INSPECTING FOR HIGH PRESSURE FUEL LEAKS FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE SKIN CAUSING PERSONAL INJURY OR DEATH INSPECT FOR HIGH PRESSURE FUEL LEAKS WITH A SHEET OF CARDBOARD WEAR SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTH ING WHEN SERVICING FUEL SYSTEM 1 Disconnect negative battery cable 2 Remove engine cover and bracket assembly Refer to 9 ENGINE COVER REMOVAL 3 Disconnect fuel pressure sensor electrical con nector Fig 6 14 8 FUEL DELIVERY FUEL RAIL Continued 4 Disconnect fuel rail return
58. hesitation rough idle engine stall ing and poor driveability OPERATION The system consists of e An EGR valve assembly The valve is located on the right side of the engine above the exhaust mani fold e An EGR solenoid The EGR solenoid controls the on time of the EGR valve e The ECM operates the EGR solenoid The ECM is located in the left rear side of the engine compart ment e The vacuum pump supplies vacuum for the EGR solenoid and the EGR valve This pump also supplies vacuum for operation of the power brake booster and the heating and air conditioning system The pump is located internally in the front of the engine block and is driven by the crankshaft gear e Vacuum lines and hoses connect the various components EXHAUST GAS RECIRCULATION 25 7 page VALVE COOLER DESCRIPTION 9 REMOVAL RAMS 9 INSTALLATION 9 SOLENOID DESCRIPTION ew eee ie eee es 9 REMOVAL racket e A 9 INSTALLATION 9 When the ECM supplies a variable ground signal to the EGR solenoid EGR system operation starts to occur The ECM will monitor and determine when to supply and remove this variable ground signal This will depend on inputs from the engine coolant tem perature throttle position and engine speed sensors When the variable ground signal is supplied to the EGR solenoid vacuum from the vacuum pump will be allowed to pa
59. line at fuel rail Fig 6 5 Disconnect fuel high pressure line from injec tion pump to fuel rail at fuel rail 6 Disconnect fuel high pressure line from fuel rail to fuel injector at fuel rail Fig 6 7 Remove fuel rail retaining bolts and remove rail from cylinder head cover intake manifold Fig 6 80cf4d1e Fig 6 FUEL SYSTEM COMPONENTS FUEL INJECTOR RETURN LINE FUEL INJECTOR RETAINING BOLT INJECTOR RETAINER HIGH PRESSURE FUEL LINE FUEL RAIL RETAINING BOLT FUEL RAIL RETURN LINE FUEL PRESSURE SENSOR FUEL RAIL 0 BOOST PRESSURF INTAKE AIR TEMPERATURE SENSOR KJ INSTALLATION WARNING HIGH PRESSURE LINES DELIVER DIE SEL FUEL UNDER EXTREME PRESSURE FROM THE INJECTION PUMP TO THE FUEL INJECTORS THIS MAY BE AS HIGH AS 1600BAR 23 200 PSI USE EXTREME CAUTION WHEN INSPECTING FOR HIGH PRESSURE FUEL LEAKS FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE SKIN CAUSING PERSONAL INJURY OR DEATH INSPECT FOR HIGH PRESSURE FUEL LEAKS WITH A SHEET OF CARDBOARD WEAR SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTH ING WHEN SERVICING FUEL SYSTEM 1 Install fue rail on cylinder head cover intake manifold Fig 6 Torque retaining bolts to 27 5N m Refer to 14 FUEL SYSTEM WARNING 2 Connect injector high pressure fuel lines at fuel rail Fig 6 3 Connect fuel rail high pressure fuel line at fuel rail 4 Connect fuel rail fuel return line at fuel rail Fig
60. marks are aligned Fig 48 2 Tighten connecting cap bolts to 29 N m 21 ft Ibs plus 60 ENGINE 9 39 3 Without loosening connecting rod bolts tighten all bolts to 88N m 4 Check and record internal diameter of crank end of connecting rod CAUTION When changing connecting rods DO NOT use a stamp to mark the cylinder location Identify the connecting rods and caps location using a paint marker All four must have the same weight and the same number Replacement con necting rods will only be supplied in sets of four Fig 48 Connecting rods are supplied in sets of four since they all must be of the same weight category Max allowable weight difference is 5 gr NOTE Lightly heat the piston in oven Insert piston pin in position and secure it with provided snap rings 80ff2917 Fig 48 CONNECTING ROD IDENTIFICATION CONNECTING ROD PAWL CONNECTING ROD PAINTED CYLINDER IDENTIFIER CONNECTING ROD BEARINGS CONNECTING ROD After having coated threads with Molyguard tighten con rod bolts to 29 N m 21 ft Ibs plus 60 PISTON PINS 1 Measure the diameter of piston pin in the cen ter and both ends 2 Piston pin diameter is 31 992 to 31 996mm 1 259524 in to 1 259681 in 9 40 ENGINE PISTON amp CONNECTING ROD Continued INSTALLATION PISTON PIN INSTALLATION 1 Secure connecting rod in soft jawed vice 2 Lubricate piston pin and piston with clean engine o
61. measurement should be 10 mm 3 8 in down and bottom measurement should be 10 mm 3 8 in up from the bottom bore INSTALLATION 1 Carefully dean liner and engine block and degrease the engine block where it comes into contact with the liners Install the liners in the engine block as shown rotating them back and forth by 45 in order to guarantee correct positioning Fig 41 NOTE All Measurements Must Be Taken On the High Pressure Pump Side KJ J9509 13 Fig 40 LINER INSPECTION 80c70677 Fig 41 LINER INSTALLATION CYLINDER LINER SHIMS O RINGS BLOCK LEDGE ENGINE BLOCK 2 Measure the liner recess relative to block deck with a dial indicator mounted on a special tool VM 1010 A Zero dial gauge on block deck 3 Move dial gauge to cylinder liner record read ing on dial gauge 4 Remove liner and special tool 5 Then select the correct shim thickness to give proper protrusion 0 00 0 05 mm 6 Fit the shim and the O rings onto the liner CYLINDER LINERS Continued 7 Lubricate the lower liner location in the block 8 Fit the liners in the crankcase making sure that the shim is positioned correctly in the seat Lock the liners in position using special tool VM 1076 and bolts Fig 42 80c6ca04 Fig 42 LINER CLAMP LOCATION 1 ENGINE BLOCK 2 LINER RETAINER VM 1076 3 CYLINDER LINER 9 Recheck the liner protrusion It should
62. priate wiring diagrams to identify shared circuits Refer to the appropriate Diesel Powertrain Diagnos tic Manual for more information STANDARD PROCEDURE PCM ECM SKIM PROGRAMMING DIESEL NOTE Before replacing the PCM ECM for a failed driver control circuit or ground circuit be sure to check the related component circuit integrity for failures not detected due to a double fault in the cir cuit Most PCM ECM driver control circuit failures are caused by internal component failures i e relay and solenoids and shorted circuits i e pull ups drivers and switched circuits These failures are difficult to detect when a double fault has occurred and only one DTC has set KJ ENGINE CONTROL MODULE Continued PCM SKIM PROGRAMMING When a PCM J TEC and the SKIM are replaced at the same time perform the following steps in order 1 Program the new PCM J TEC 2 Program the new SKIM 3 Replace all ignition keys and program them to the new SKIM ECM SKIM PROGRAMMING When an ECM Bosch and the SKIM are replaced at the same time perform the following steps in order 1 Program the new SKIM 2 Program the new ECM Bosch PROGRAMMING THE ECM Bosch 1 To program the VIN connect the DRB 1119 and turn the ignition on 2 Select Engine from the main menu The DRB 1119 will require the VIN to be entered before con tinuing 3 Select ENTER to update the VIN The DRB 1119 will display the updated VIN 4 If
63. relay control circuit is activated when the igni tion key is switched ON without the engine run ning Post Heat is the amount of time the glow plug relay control circuit is activated after the engine is operated The Glow Plug lamp will not be activated during the post heat cycle Wait To Start Lamp Temperature ON Plugs On Key Seconds Seconds Pre Heat Cycle Glow Post Heat Cycle Seconds Engine Coolant KJ ENGINE TABLE OF CONTENTS page ENGINE 2 5L 2 8L TURBO DIESEL DESCRIPTION DESCRIPTION 2 5L 2 8L COMMON RAIL DIESEL ENGINE 8 DESCRIPTION ENGINE COVER 3 REMOVAL REMOVAL M 3 REMOVAL ENGINE COVER 5 INSTALLATION INSTALLATION 5 INSTALLATION ENGINE COVER 6 SPECIFICATIONS SPECIFICATIONS 2 8L COMMON RAIL DIESEL ENGINE 6 SPECIFICATIONS TORQUE 8 SPECIAL TOOLS 11 CYLINDER HEAD STANDARD PROCEDURE STANDARD PROCEDURE VALVE 15 STANDARD PROCEDURE MEASURING PISTON PROTRUSION 17 REMOVAL 17 CLEANING 19 INSPECTION 19 INSTALLATION 19 CAMSHAFT OIL SEAL S REMOVAL as eis 21 INSTALLATION 22 CAMSHAFT S DESCRIPTION 22 OPERAT
64. remove the condenser from the vehicle 17 Remove power steering cooler retaining bolts and undip the air deflectors from both sides of the radiator cooling module assembly 18 Lift cooling module assembly out of the engine bay 19 Remove radiator retaining bolts and remove the cooling system module from vehicle 20 Separate charge air cooler from radiator INSTALLATION 1 Install radiator on the charge air cooler and install retaining bolts 2 Install radiator cooling module assembly in the engine bay 3 Install power steering cooler retaining bolts and clip the air deflectors on both sides of the radia tor cooling module assembly 4 Install condenser assembly and retaining bolts 5 Install low side refrigerant line and retaining nut 6 Connect coolant reservoir hose on the radiator 7 Connect engine coolant hoses on the radiator 8 Connect charge air cooler hoses on the charge air cooler 9 Install fan and fan shroud assembly and retaining bolts 10 Install cooling fan assembly to cooling fan support 11 Install high side refrigerant line and retaining nut 12 Install upper radiator support bracket and retaining bolts 13 Connect high side refrigerant line on the upper radiator support bracket 14 Evacuate and recharge the refrigerant sys tem Refer to 24 HEATING amp AIR CONDITION ING PLUMBING STANDARD PROCEDURE 15 Install air filter assembly in the engine bay
65. sealant to bottom of fuel pump module metal access plate 12 Install fuel pump module metal access plate and 4 nuts Tighten nuts to N m 26 in 165 torque 13 Position carpet and install 2 new cargo damp rivets into each cargo holdown clamp KJ FUEL LEVEL SENDING UNIT SENSOR DESCRIPTION The fuel gauge sending unit fuel level sensor is attached to the side of the lower fuel tank module The sending unit consists of a float an arm and a variable resistor track card OPERATION For Fuel Gauge Operation A constant current source of approximately 32 milliamps is supplied to the resistor track on the fuel gauge sending unit This is fed directly from the Engine Control Module ECM NOTE For diagnostic purposes this 12V power source can only be verified with the cir cuit opened fuel tank module electrical con nector unplugged With the connectors plugged output voltages will vary from about 0 6 volts at FULL to about 8 6 volts at EMPTY about 8 6 volts at EMPTY for J eep models and about 7 0 volts at EMPTY for Dodge Truck mod els The resistor track is used to vary the voltage resistance depending on fuel tank float level As fuel level increases the float and arm move up which decreases voltage As fuel level decreases the float and arm move down which increases voltage The varied voltage signal is returned back to the ECM through the sensor return circuit Both of the electrical circuits between
66. starter mounting location on the engine block 39 Remove exhaust inlet pipe retaining bolts and disconnect exhaust pipe from turbocharger 40 Remove transmission to engine retaining bolts 41 Lower vehicle 42 Connect a suitable lifting device to engine assembly 43 Remove right side engine mount from engine block 44 Disconnect crankshaft position sensor located on the right rear of the engine 45 Disconnect oil pressure sensor located between the engine block and the turbocharger Make certain everything is disconnected from the engine assembly 46 Place a floor jack under the transmission to support the transmission 47 With engine and transmission supported by a lifting device carefully separate the engine from the transmission 48 Lift the engine assembly out of the engine bay ENGINE 9 5 ENGINE 2 5L 2 8L TURBO DIESEL Continued REMOVAL ENGINE COVER 1 Remove oil fill cap and oil dipstick 2 Carefully lift engine engine cover from corners to remove from mounting bracket Fig 2 LS TX AY iN Sie Y 2 Q5 1124 y 8 222 SS oy 80 487 7 Fig 2 ENGINE COVER REMOVAL INSTALLATION 1 ENGINE COVER BRACKET 2 ENGINE COVER RETAINING BOLTS INSTALLATION INSTALLATION 1 Install engine assembly in the engine bay 2 Line up the transmission input shaft with the c
67. the cooling system This is done using air pressure in the opposite direction of normal coolant flow It is usually only necessary with very dirty systems with evidence of partial plugging If visual inspection indicates the formation of sludge or scaly deposits use a radiator cleaner Mopar Radiator Kleen or equivalent before flushing This will soften scale and other deposits and aid the flushing operation CAUTION Be sure instructions on the container are followed REVERSE FLUSHING RADIATOR Disconnect the radiator hoses from the radiator fit tings Attach a section of radiator hose to the radia tor bottom outlet fitting and insert the flushing gun Connect a water supply hose and air supply hose to the flushing gun 7 8 COOLING 2 5L 2 8L TURBO DIESEL KJ COOLING 2 5L 2 8L TURBO DIESEL Continued CAUTION The cooling system normally operates at 97 to 110 kPa 14 to 16 psi pressure Exceeding this pressure may damage the radiator or hoses Allow the radiator to fill with water When radiator is filled apply air in short blasts allowing radiator to refill between blasts Continue this reverse flushing until clean water flows out through rear of radiator cooling tube passages For more information refer to operating instructions supplied with flushing equip ment Have radiator cleaned more extensively by a radiator repair shop REVERSE FLUSHING ENGINE Drain the cooling system Refer to 7 COOLING STANDARD P
68. to the engine provides Improved engine performance e Lower exhaust smoke density Improved operating economy e Altitude compensation e Noise reduction 0 1001 01 11 6 EXHAUST SYSTEM AND TURBOCHARGER TURBOCHARGER Continued WASTEGATE CLOSED PTL SSS zy 80bfeO0b6 Fig 8 Turbocharger Wastegate Actuator 1 TURBOCHARGER 2 DIAPHRAGM 3 WASTE GATE ACTUATOR The turbocharger also uses a wastegate Fig 9 which regulates intake manifold air pressure and prevents over boosting at high engine speeds When the wastegate valve is closed all of the exhaust gases 9 8065 53 flow through the turbine wheel As the intake mani fold pressure increases the wastegate actuator opens Fig 9 Wastegate Operation j j 1 SIGNAL LINE the valve diverting some of the exhaust gases away os EVAL st BYPASS VAINE from the turbine wheel This limits turbine shaft 3 WASTEGATE speed and air output from the impeller 4 EXHAUST j j j j j 5 TURBINE The turbocharger 15 lubricated by engine oil that is 2 08 02 pressurized cooled and filtered The oil is delivered 7 WASTEGATE to the turbocharger by a supply line that is tapped 8 EXHAUST into the block The oil travels into the bearing hous S SIGNE LINE ing where it lubricates the shaft and bearings Fig 10 A return pipe at the bottom of the bearing hous ing routes the engine oil back to the cra
69. tool VM 1055 Fig 9 torque high pressure injection pump sprocket retaining nut to 88 3 7 Connect fuel pressure solenoid electrical con nector 8 Connect fuel supply and return lines at high pressure injection pump Fig 13 Refer to 14 FUEL SYSTEM WARNING 9 Install outer timing belt cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 10 Install fan support assembly Refer to 7 COOLING ENGINE RADIATOR FAN INSTALLA TION 11 Install accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 12 Install cooling fan and shroud assembly 13 Install charge air cooler outlet hose 14 Install engine cover and bracket Refer to 9 ENGINE INSTALLATION 15 Connect negative battery cable 16 Evacuate and recharge A C system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE gt 22 MT 80 14149 Fig 13 FUEL INJECTION PUMP REMOVAL INSTALLATION BANJO FITTING BRASS WASHERS FUEL INLET LINE FUEL OUTLET LINE BANJO FITTING INJECTION PUMP RETAINING NUT INJECTION PUMP MOUNTING STUDS INNER TIMING COVER SEAL INNER TIMING COVER RETAINING BOLT RETAINING BOLT RETAINING BOLT HOSE CLAMP CYLINDER HEAD COVER INTAKE MANIFOLD FUEL RETURN LINE TO INJECTION PUMP HOSE CLAMP FUEL RETURN JUNCTION BL
70. trouble code to set a specific set of conditions must occur and unless these conditions occur a DTC will not set DIAGNOSTIC TROUBLE CODES Each diagnostic trouble code DTC is diagnosed by following a specific procedure The diagnostic test procedure contains step by step instruction for deter mining the cause of the DTC as well as no trouble code problems Refer to the appropriate Diesel Pow ertrain Diagnostic Manual for more information HARD CODE A DTC that comes back within one cycle of the ignition key is a hard code This means that the problem is current every time the ECM SKIM checks that circuit or function Procedures in this manual verify if the DTC is a hard code at the beginning of each test When the fault is not a hard code an intermittent test must be performed NOTE If the DRBIII displays faults for multiple components i e ECT VSS IAT sensors identify and check the shared circuits for possible problems before continu ing i e sensor grounds or 5 volt supply circuits Refer to the appropriate schematic to identify shared circuits Refer to the appropriate Diesel Powertrain Diagnostic Manual for more information KJ INTERMITTENT CODE A DTC that is not current every time the ECM SKIM checks the circuit or function is an intermit tent code Most intermittent DTCs are caused by wiring or connector problems Problems that come and go like this are the most difficult to diagnose they must be looked for
71. vibration damper and retaining bolts Torque bolts to 27 5N m 2 Install accessory drive belt Refer to 7 COOL ING ACCESSORY DRIVE DRIVE BELTS INSTAL LATION 3 Install viscous fan and fan shrowd Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH INSTALLATION 4 Connect negative battery cable INTERNAL VACUUM PUMP DESCRIPTION The diesel engine uses a internal vacuum pump This vacuum pump is mounted in the front of the engine block under the engine front cover Fig 55 The vacuum pump is driven by a sprocket on the crankshaft REMOVAL 1 Disconnect negative battery cable KJ 80c6c9ea Fig 55 VACUUM PUMP 2 Remove cooling fan and fan drive viscous clutch assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 3 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 4 Remove cooling fan support Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL 5 Remove vibration damper crankshaft pulley Refer to 9 BLOCK VIBRATION DAMPER REMOVAL 6 Remove outer timing belt cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 7 Remove timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL 8 Remove timing belt inner cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL NOTE Crankshaft hub has LHD thread 9
72. 1 18 9451194 uv39 L93HIG NI MOTA Ol TnVHdGAH 9290808 0091 1 NO 29 440929 08 01 err se 591 56 6 D 4 i 54 54 5 4 are 54 4 PAA ALL i 2 412522 4 i 122227 m S rm T asses 14 14 Q31VA3 T3 HOSN3S S3Hd SNIT Sd1 105 TOHLNOO 53 4 504 ov 1081368 11011 511 HOLIMS S3Hd Sd dV 5 14 19 H31H3ANOO 90 Fo 20 i HOLA 10 Puz oz 3Su3A3H 6 2 1 aavstiv4 uvao 10381 99 21 19 AUTOMATIC TRANSMISSION 545RFE AUTOMATIC TRANSMISSION 545RFE Continued 856590208 IOWA 9939 LO3HIG NI 25 43099 08 65 o 991 56 8 5 E 14 O31vA313 E HOSN3s 58 SNIT Sd1 105 TOHLNOO s3ud sod f 10374S ILINW SW HOLIMS S3Hd Sd E 3unssa3ud 1d 10 H31H3ANOO 09 YOLVINNNDOV 0V HOLN10 uip 2r 3suaAau od HO1m 2 3SH3A3H MO1 Y1 003 uv3o Lo3ulg Y AUTOMATIC TRANSMISSION 545
73. 1 Remove rocker arms from lifters Fig 21 5 0 9 vN J 5 9 y AZ QU 2 VAY iB Xu AAW 80fecfda Fig 21 ROCKER ARM ASSEMBLY ROCKER ARM ASSEMBLY CYLINDER HEAD COVER INTAKE MANIFOLD HYDRAULIC LIFTER CYLINDER HEAD VALVE INSTALLATION 1 Clean and inspect gasket sealing surfaces 2 Install new gasket on cylinder head 3 Lubricate lifter ball end of lifter s valve s and rocker arm roller s with Mopar Engine Oil Supplement or equivlalent 4 Connect rocker arm s to lifter and reposition on valve s 5 Install cylinder head cover intake manifold Refer to 9 ENGINE CYLINDER HEAD CYLIN DER HEAD COVER S INSTALLATION 6 Install inner timing belt cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 7 Install timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION 8 Install outer timing belt cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 9 Install vibration damper ENGINE 9 27 10 Install cooling fan support Refer to 7 COOL ING ENGINE RADIATOR FAN INSTALLATION 11 Install accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 12 Install cooling fan and fan drive viscous clutch assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH INS
74. 11 EXHAUST SYSTEM TURBO CHARGER SYSTEM TURBOCHARGER REMOVAL KJ INSTALLATION 1 Refer to 11 EXHAUST SYSTEM TURBO CHARGER SYSTEM TURBOCHARGER INSTAL LATION VALVE TIMING STANDARD PROCEDURE LOCKING ENGINE 90 DEGREES AFTER TDC 1 Disconnect negative battery cable 2 Rotate engine by hand until special tool VM 8873 can be install in engine to transmission adapter plate on right side of engine looking at the engine from the flywheel This will lock the engine at 90 after TDC 3 Remove engine cover Refer to 9 ENGINE COVER REMOVAL 4 Remove EGR valve and EGR cooler to exhaust manifold retaining nuts 5 Reposition EGR valve assembly out of way 6 Remove plug in cylinder head cover intake manifold and insert VM 1053 to lock exhaust cam shaft in position 7 Remove generator Refer to 8 ELECTRICAL CHARGING GENERATOR REMOVAL 8 Remove plug in cylinder head cover intake manifold and insert VM 1052 to lock intake camshaft in position 9 At this point the timing belt can be removed for service 10 After engine service is completed and timing belt reinstalled remove both camshaft locking pins from cylinder head cover intake manifold 11 Install both camshaft access plugs 12 Remove 90 after TDC engine locking pin 13 Install generator Refer to 8 ELECTRICAL CHARGING GENERATOR INSTALLATION 14 Install engine cover Refer to 9 ENGINE COVER INSTALLATION 1
75. 1c8d Fig 2 MIDTRONICS TESTER Always use the Micro 420 Instruction Manual that was supplied with the tester as a reference If the Instruction Manual is not available the following pro cedure can be used WARNING ALWAYS WEAR APPROPRIATE EYE PROTECTION AND USE EXTREME CAUTION WHEN WORKING WITH BATTERIES BATTERY TESTING 1 If testing the battery OUT OF VEHICLE clean the battery terminals with a wire brush before test ing If the battery is equipped with side post termi nals install and tighten the supplied lead terminal stud adapters Do not use steel bolts Failure to prop erly install the stud adapters or using stud adapters that are dirty or worn out may result in false test readings 2 If testing the battery IN THE VEHICLE make certain all of the vehicle accessory loads are OFF including the ignition The preferred test position is at the battery terminal If the battery is not accessible you may test using both the positive and negative jumper posts Select TESTING AT JUMPER POST when connecting to that location 3 Connect the tester Fig 2 to the battery or jumper posts the red damp to positive and the black damp to negative KJ NOTE Multiple batteries connected in parallel must have the ground cable disconnected to perform a battery test Failure to disconnect may result in false battery test readings NOTE When testing the battery in a PT Cruiser always test at the battery terminals
76. 2 Position the transmission solenoid TRS assem bly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate 3 Install the screws to hold the transmission solenoid TRS assembly onto the valve body 4 Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first Tighten the screws to 5 7 N m 50 165 5 Tighten the remainder of the solenoid assembly screws to 5 7 N m 50 165 6 Install the valve body into the transmission VALVE BODY DESCRIPTION The valve body consists of a cast aluminum valve body a separator plate and a transfer plate The valve body contains valves and check balls that con trol fluid delivery to the torque converter clutch bands and frictional clutches The valve body contains the following components Fig 27 and Fig 28 e Solenoid switch valve Manual valve Low reverse switch valve 5 Accumulators 7 check balls 21 44 VALVE BODY Continued AUTOMATIC TRANSMISSION 545RFE KJ 808a2e54 Fig 27 Valve Body Components 1 LOW REVERSE ACCUMULATOR 6 OVERDRIVE ACCUMULATOR 2 LOW REVERSE SWITCH VALVE 7 UNDERDRIVE ACCUMULATOR 3 UPPER VALVE BODY 8 4C ACCUMULATOR 4 MANUAL VALVE 9 2C ACCUMULATOR 5 SOLENOID SWITCH VALVE OPERATION
77. 255 ont ed suns 21 INSTALLATION 21 CRANKSHAFT POSITION SENSOR DESCRIPTION The crankshaft position sensor is mounted in the right rear of the engine block below the turbocharger Fig 1 This sensor is used to detect engine speed OPERATION The crankshaft position sensor 15 a magnetic pickup type sensor that generates an A C signal The sensor contains a permanent magnet and a coil of wire The sensor generates A C signal each time notch in the reluctor wheel on the crankshaft passes across the permanent magnet The ECM calculates engine speed based on the frequency of the A C sig nal REMOVAL 1 Disconnect negative battery cable 2 Raise vehicle on houst 3 Remove exhaust pipe to turbocharger down pipe retaining bolts and lower exhaust pipe from tur bocharger downpipe 4 Disconnect crankshaft position sensor electrical connector 5 Remove crankshaft position sensor retaining bolt and remove sensor from engine block Fig 2 KJ page INTAKE AIR TEMPERATURE SENSOR DESCRIPTION 21 OPERATION 21 REMOVAL i t d c 21 INSTALLATION 21 FUEL INJECTOR DESCRIPTION FUELINJECTOR 22 OPERATION wade 22 REMOVAL 2 ogee teed ee 23 INSTALLATION 23 FUEL PRESSURE SENSOR DESCRIPTION
78. 3 Remove crankshaft sprocket 14 Remove oil pan Refer to 9 ENGINE LUBRI CATION OIL PAN REMOVAL 15 Remove oil pump pickup tube Refer to 9 ENGINE LUBRICATION OIL PUMP REMOVAL 9 30 ENGINE CRANKSHAFT Continued 16 Remove balance shaft assembly Refer to 9 ENGINE VALVE TIMING BALANCE SHAFT REMOVAL 17 Remove oil jets Refer to 9 ENGINE LUBRI CATION OIL J ET REMOVAL 18 Remove piston and connecting rod assemblies Refer to 9 ENGINE ENGINE BLOCK PISTON amp CONNECTING ROD REMOVAL 19 Slide special tool VM 1069 on crankshaft Fig 27 80 52 Fig 27 CRANKSHAFT SLEEVE VM 1069 1 CRANKSHAFT SLEEVE VM 1069 2 ENGINE BLOCK 20 Using special tool VM 1054 remove crank shaft support retainers and o rings Fig 28 21 Slide crankshaft out rear of engine block INSTALLATION 1 Install crankshaft in engine block Be sure to align oil holes in crankshaft supports and engine block 2 Install crankshaft support retainers Fig 29 3 Remove special tool VM 1069 from crankshaft Fig 27 4 Install crankshaft sprocket 5 Install front engine cover Refer to 9 ENGINE ENGINE BLOCK ENGINE COVER INSTALLATION 6 Install rear main bearing support in engine block Fig 26 Be sure to align oil hole in rear main bearing support with hole in block 7 Install adapter plate and retaining bolts Torque bolts to 27 5N m KJ o o 80fef7ea
79. 4 A normal condition No correction needed Gauge should return to normal after a few minutes of engine operation 5 Check and correct coolant leaks 6 a Check for cylinder head gasket leaks with a commercially available leak tester b Check for coolant in engine oil Inspect for white steam emitting from exhaust System Repair as necessary 7 Check water pump and replace as necessary 8 Check and correct as necessary 9 Locate leak and repair as necessary PRESSURE CAP IS BLOWING OFF STEAM AND OR COOLANT TEMPERATURE GAUGE READING MAY BE ABOVE NORMAL BUT NOT HIGH COOLANT LEVEL MAY BE HIGH IN COOLANT TANK 1 Pressure relief valve in pressure vent cap is defective 2 Head gasket leak or cracked cylinder head 1 Check condition of pressure vent cap and cap seals 2 Repair as necessary COOLANT LOSS TO THE GROUND WITHOUT PRESSURE CAP BLOWOFF GAUGE IS READING HIGH OR HOT 1 Coolant leaks in radiator cooling System hoses water pump or engine 1 Pressure test cooling system and repair as necessary 1 6 COOLING 2 5L 2 8L TURBO DIESEL COOLING 2 5L 2 8L TURBO DIESEL Continued CONDITION POSSIBLE CAUSES KJ CORRECTION HOSE OR HOSES COLLAPSE WHEN ENGINE IS COOLING 1 Vacuum created in cooling system on engine cool down is not being relieved through pressure vent cap 1 Cap relief valve stuck Replace if necessary NOISY FAN 1 Cooling fan blad
80. 47 1 35 Bolts Vibration Damper to Crankshaft Hub Bolts Crankshaft Crankshaft Support Bolts Bolts PA 1 Crankshaft Suppor Pols to Exhaust 32 IL Manifold Nuts KJ ENGINE 9 11 ENGINE 2 5L 2 8L TURBO DIESEL Continued SPECIAL TOOLS 80c49992 VM 1050 CRANKSHAFT REAR SEAL INSTALLER 80c143ba VM 1052 INTAKE CAMSHAFT ALIGNMENT PIN 80c1449e VM 1053 EXHAUST CAMSHAFT ALIGNMENT PIN 80 14546 VM 1054 RELIEF VALVE REMOVER CENTRAL CARRIER REMOVER INSTALLER C 80c13cec VM 1055 CAMSHAFT HIGH PRESSURE INJECTION PUMP GEAR HOLDER 80c17320 VM 1056 BALANCE SHAFT LOCKING PIN 9 1 ENGINE KJ ENGINE 2 5L 2 8L TURBO DIESEL Continued 80c17ba4 VM 1062 POWER STEERING PUMP INSTALLER 80c1570a VM 1059 OIL PRESSURE RELIEF VALVE INSTALLER q 80c17f19 VM 1060 OIL JET REMOVER INSTALLER 80c499a4 VM 1063 FUEL INJECTOR REMOVER 80c17810 VM 1061 FRONT COVER AND FRONT OIL SEAL INSTALLER 9 13 ENGINE 2 5L 2 8L TURBO DIESEL Continued TM 80c17fce VM 1064 POWER STEERING PUMP GEAR 80 9744 REMOVER VM 1067 HIGH PRESSURE PUMP REMOVER 80 17151 VM 1069 CRANKSHAFT REM INSTALL SLEEVE 80 17156 VM 1065 PISTON RING COMPRESSOR 80 17740 80 144 1070 FLYWHEEL
81. 5 15 Remove snapring and thrust washer from camshaft Fig 15 16 Slide camshaft through access hole at rear of cylinder head cover intake manifold INSTALLATION 1 Lubricate camshafts with Mopar Engine Oil Supplement or equivalent 2 Carefully install camshafts into access holes in rear of cylinder head cover intake manifold 3 Install thrust washer snapring and camshaft oil seal Fig 15 4 Install access hole plugs and gaskets at rear of cylinder head cover intake manifold Torque plugs to 80N m 5 Install cylinder head cover intake manifold on engine block Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S INSTALLA TION 6 Install timing belt inner cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 7 Install timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION ENGINE 9 23 80c58e2b Fig 15 CAMSHAFT ASSEMBLY INTAKE CAMSHAFT SNAPRING CAMSHAFT OIL SEAL THRUST WASHER CYLINDER HEAD COVER INTAKE MANIFOLD EXHAUST MANIFOLD 8 Install timing belt outer cover Refer to 9 TIMING TIMING BELT CHAIN COVER S INSTALLATION 9 Install generator Refer to 8 ELECTRICAL CHARGING GENERATOR INSTALLATION 10 Install vibration damper 11 Install cooling fan support Refer to 7 COOL ING ENGINE RADIATOR FAN INSTALLATION 12 Ins
82. 5 Connect negative battery cable KJ BALANCE SHAFT DESCRIPTION The 2 5L and 2 8L Common Rail Diesel engine is equipped with two nodular cast iron balance shafts in a cast aluminum carrier The balance shaft assem bly is mounted to the engine block Fig 68 81069fd6 Fig 68 OIL PICK UP TUBE AND BALANCE SHAFT ASSEMBLY 1 BALANCE SHAFT RETAINING BOLTS 2 BALANCE SHAFT ASSEMBLY 3 OIL JET RETAINING BOLT 4 OIL JET 5 CENTRAL CARRIER PINS 6 ENGINE BLOCK 7 CENTRAL CARRIER PIN O RINGS 8 OIL PUMP PICK UP TUBE O RINGS 9 OIL PUMP PICK UP TUBE 10 OIL PICK UP TUBE RETAINING BOLT OPERATION The balance shaft is driven by the crankshaft The balance shafts are connected by heelical gears The dual counter rotating shafts decrease second order vertical shaking forces caused by component move ment ENGINE 9 51 REMOVAL 1 Disconnect negative battery cable 2 Raise vehicle on hoist 3 Remove oil pan Refer to 9 ENGINE LUBRI CATION OIL PAN REMOVAL 4 Remove oil pump pickup tube Refer to 9 ENGINE LUBRICATION OIL PUMP REMOVAL 5 Remove balance shaft assembly Fig 69 81069fd6 Fig 69 OIL PICK UP TUBE AND BALANCE SHAFT ASSEMBLY 1 BALANCE SHAFT RETAINING BOLTS 2 BALANCE SHAFT ASSEMBLY 3 OIL JET RETAINING BOLT 4 OIL JET 5 CENTRAL CARRIER PINS 6 ENGINE BLOCK 7 CENTRAL CARRIER PIN O RINGS 8 OIL PUMP PICK UP TUBE O RINGS 9 OIL PUMP PICK UP T
83. 66590808 iy 44099 de isdsaunssaud 98S 811 96 CoL Ge ERIS mm rrr 1 5 III ld IN3A A HOSN3S 8 11 641 106 TOHLNOO e3ud Sod 103138 11 11 5 1 HOLIMS S3Hd Sd 3unssaud 1d 22 19 1 YHOLWINNINDOV OV ER 1 19 Ute ot 10 5 go an HOLNTO lt MOT H1 99 ARS 94751194 uvao 5 Kj TRANSMISSION 545RFE 21 27 AUTOMATIC TRANSMISSION 545RFE Continued SPECIFICATIONS Component merc mon UD Clutch Pack 0 84 1 54 0 033 0 061 GENERAL 0 22 0 55 0 009 0 021 mm in 0 46 0 89 0 018 0 035 mm in 0 455 1 335 0 018 0 053 mm in m n m n Reverse Clutch Pack 0 81 1 24 0 032 0 049 Clearance mm in Recommended fluid Mopar ATF 4 GEAR RATIOS m 1 00 1 74 0 039 0 069 m i 1 103 1 856 0 043 0 073 mm in TORQUE SPECIFICATIONS 0 770 1 390 0 030 0 055 in Screw accumulator cover Screw detent spring Bolt input speed sensor 21 28 AUTOMATIC TRANSMISSION 545RFE HOLDING CLUTCHES DESCRIPTION Three hydraulically applied multi disc clutches are used to hold some planetary geartrain components stat
84. 81 Fan 2 Control Circuit Open Circuit Fan 2 Control Circuit Short Circuit KJ ON BOARD DIAGNOSTICS 25 5 ON BOARD DIAGNOSTICS Continued Generic Scan Tool Code DRB Scan Tool Display P0500 Vehicle Speed Sensor Frequency Too High Vehicle Speed Sensor Frequency High Level Duration Vehicle Speed Sensor Plausibility Vehicle Speed Sensor Signal Voltage Too High Battery Temperature Sensor Circuit Signal Voltage Too High Oil Pressure Sensor Circuit MALF Signal Voltage Too High Oil Pressure Sensor Circuit MALF Signal Voltage Too Low Oil Pressure Sensor Circuit MALF Signal Voltage Too Low or High A C Pressure Sensor Circuit Plausibility A C Pressure Sensor Circuit Signal Voltage Too High A C Pressure Sensor Circuit Signal Voltage Too Low A C Pressure Sensor Circuit Supply Voltage Too High Or Low System Voltage Too High System Voltage Too Low Speed Control Switch Signal Circuit Voltage Too High Speed Control Switch Signal Circuit Voltage Too Low ECM Error Gate Array Communication ECM Error Gate Array Communication Not Verified ECM Error Gate Array Quantity Stop ECM Error Gate Array Has Occurred ECM Error Redundant Overrun Monitoring Starter Relay Circuit Open Circuit Starter Relay Circuit Short Circuit Generator Field Control MALF Open Circuit Generator Field Control MALF Short Circuit Sensor Reference Voltage A CKT Voltage Too High Sensor Reference Voltage A CKT Voltage To
85. AL INSTALLATION TIMING BELT CHAIN COVER S REMOVAL REMOVAL TIMING BELT INNER COVER REMOVAL TIMING BELT OUTER COVER INSTALLATION INSTALLATION TIMING BELT INNER COVER soe pepe E SUR e Bae INSTALLATION TIMING BELT OUTER COVER TIMING BELT IDLER PULLEY REMOVAL INSTALLATION TIMING BELT CHAIN AND SPROCKET S REMOVAL INSTALLATION TIMING BELT CHAIN TENSIONER amp PULLEY REMOVAL INSTALLATION ADJUSTMENTS ADJUSTMENT TIMING BELT TENSIONER KJ ENGINE 2 5L 2 8L TURBO DIESEL DESCRIPTION DESCRIPTION 2 5L 2 8L COMMON RAIL DIESEL ENGINE The 2 5 Liter 2500cc and 2 8L 2800cc four cylin der common rail direct injection engines are very simular in design and operability with a few differ ences The 2 5L is the engine of choise from the man ual transmission and the 2 8L for the automatic transmission Both 4 cylinder common rail direct injection engines are in line overhead valve design The engines utilize a cast iron cylinder block and an aluminum cylinder head with four valves per cylinder and dual overhead cam shafts Both engins are turbocharged and intercooled Differences include a longer crankshaft gear larger cylinder bore and larger intake ducts in the cylinder head of the 2 8L The 2 8L is also equipped with a EGR cooler Fig 1 1755 Automatic Belt Tensioner Cooling System Capacity 13 8 Liters W O Auxiliary Heater 16 6 Liters
86. AL INSTALLATION 1 TIMING BELT INNER COVER 2 CAMSHAFT SPROCKET 3 IDLER PULLEYS 4 CAMSHAFT SPROCKET 5 VM 1055 9 Remove both camshaft oil seals INSTALLATION 1 Install new camshaft oil seal using VM 1057 2 Install camshaft sprockets and tighten retain ing bolts finger tight 3 Install timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION 4 Torque camshaft sprockets to 108 N m using VM 1055 to hold sprockets Fig 13 5 Install outer timing belt cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 6 Install vibration damper 7 Install cooling fan support Refer to 7 COOL ING ENGINE RADIATOR FAN INSTALLATION KJ 8 Install accessory drive belt Refer to 7 COOL ING ACCESSORY DRIVE DRIVE BELTS INSTAL LATION 9 Install cooling fan and fan drive viscous clutch assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH INSTALLATION 10 Connect negative battery cable CAMSHAFT S DESCRIPTION The camshafts are made of gray cast iron with eight machined lobes and four bearing journals Fig 14 80c58df5 Fig 14 CAMSHAFTS 1 INTAKE CAMSHAFT 2 EXHAUST CAMSHAFT OPERATION When the camshaft rotates the lobes actuate the hydraulic lifters and rocker arms forcing downward on the rocker arms which opens the valves REMOVAL 1 Disconnect negative battery cable 2 Remove e
87. CAUSING PERSONAL INJURY OR DEATH INSPECT FOR HIGH PRESSURE FUEL LEAKS WITH A SHEET OF CARDBOARD WEAR SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTH ING WHEN SERVICING FUEL SYSTEM 1 Disconnect negative battery cable 2 Remove engine cover and bracket Refer to 9 ENGINE REMOVAL 3 Evacuate A C system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE 4 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 5 Remove cooling fan and fan shroud KJ 6 Remove charge air cooler outlet hose to intake manifold 7 Remove fan support assembly Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL 8 Remove timing belt outer cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 9 Using special tool VM 1055 remove high pres sure injection pump sprocket retaining nut Fig 9 80 51499 Fig 9 INJECTION PUMP SPROCKET RETAINING NUT REMOVAL INSTALLATION IDLER PULLEY TIMING BELT VM 1055 INJECTION PUMP SPROCKET NOTE The use of special tool 1067 will allow you to remove the high pressure injection pump without removing the timing belt from the engine This will allow you to remove and install the high pressure injection pump without altering injection pump timing 10 Install feet from VM 1067 in injection pump sprocket as shown Fig 10 11 Install inner flange of special too
88. CONNECTING ROD BOLT CONNECTING ROD BEARING CONNECTING ROD SNAP RING PISTON RING REMOVAL 1 ID mark on face of top and second piston rings must point toward piston crown KJ PISTON amp CONNECTING ROD Continued 2 Using a suitable ring expander remove top and second piston rings Fig 47 Fig 47 PISTON RINGS REMOVAL INSTALLATION 3 Remove upper oil ring side rail lower oil ring side rail and then the oil expander from piston 4 Carefully clean carbon from piston crowns skirts and ring grooves ensuring the 4 oil holes in the oil control ring groove are clear INSPECTION PISTONS 1 Piston Diameter Size 91 912 91 928 3 6185 3 6192 in Maximum wear limit 05mm 0019 in 2 Check piston pin bores in piston for roundness Make 3 checks at 120 intervals Maximum out of roundness 05mm 0019in 3 The piston diameter should be measured approximately 15 mm 590 in up from the base 4 Skirt wear should not exceed 0 1 mm 00039 in 5 The clearance between the cylinder liner and piston should not exceed 0 065 0 083 mm 0025 0032 in CONNECTING RODS CAUTION When assembling the connecting rod be sure that the pawl on each of the connecting rod caps is facing the rear fly wheel side of the engine Fig 48 1 Assemble bearing shells and bearing caps to their respective connecting rods ensuring that the serrations on the cap and reference
89. D SPROCKETS CAMSHAFT SPROCKETS INJECTION PUMP SPROCKET INJECTION PUMP SPROCKET RETAINING NUT TIMING BELT TIMING BELT TENSIONER RETAINING BOLT TIMING BELT TENSIONER TENSIONER ALIGNMENT PIN IDLER PULLEY CAMSHAFT SPROCKET RETAINING BOLT 15 Remove the intake exhaust camshaft alignment pins 16 Loosen camshaft gears using special tool VM 1055 to retain the gears when removing bolts 17 Use camshaft bolt to rotate the intake cam shafts until the intake alignment hole lines up with the hole on the camshaft cover Install alignment pin VM 1052 and tighten with a wrench repeat the oper ation for the exhaust camshaft alignment using alignment pin VM 1053 INSTALLATION 1 With both camshaft alignment pins still installed and the engine locked at 90 after TDC ver ify that the camshaft gears are loose 2 Align timing mark on high pressure injection pump gear with timing mark on cover Fig 77 80 75938 Fig 77 INJECTION PUMP GEAR TIMING MARKS 1 TIMING MARK ON COVER 2 TIMING MARK ON INJECTION PUMP SPROCKET 3 INJECTION PUMP SPROCKET NOTE DO NOT remove the timing belt from the package uniil it s ready to be installed DO NOT expose timing belt to oil grease or water contami nation DO NOT crimp belt at a sharp angle DO NOT clean belt pulleys or tensioner with solvent Check that pulleys and bearings are not seized or damage before insta
90. E REMOVAL 1 Disconnect negative battery cable 2 Disconnect EGR solenoid electrical connector Fig 3 3 Disconnect both vacuum lines at solenoid Fig 3 4 Remove EGR solenoid from rubber mount Fig 3 INSTALLATION 1 Install EGR solenoid in rubber mount Fig 3 2 Connect EGR solenoid vacuum lines Fig 3 3 Connect EGR solenoid electrical connector Fig 3 4 Connect negative battery cable SERVICE MANUAL COMMENTS What errors s have you found In order for us to assist you please include as much details as possible when reporting an error Comments Suggestions Dealership Technician Retail Customer Dealer Code Manual Title Year Number and Page Your Name Address All comments become property of DaimlerChrysler Corporation and may be used without compensation Fold Here DaimlerChrysler Corporation Attn Publications Dept CIMS 486 02 70 800 Chrysler Drive Auburn Hills 48326 2757 Fold Here l 1 1 4 1 1 1 1 l 4 1 l
91. E MANIFOLD akonh 5 Install engine cover Refer to 9 ENGINE COVER INSTALLATION 6 Connect negative battery cable FAN DRIVE VISCOUS CLUTCH DESCRIPTION CAUTION If the viscous fan drive is replaced because of mechanical damage the cooling fan blades should also be inspected Inspect for fatigue cracks loose blades or loose rivets that could have resulted from excessive vibration Replace fan blade assembly if any of these conditions are found Also inspect water pump bearing and shaft assembly for any related damage due to a viscous fan drive malfunction The thermal viscous fan drive Fig 8 is a silicone fluid filled coupling used to connect the fan blades to the fan support bracket assembly The coupling allows the fan to be driven in a normal manner This is done at low engine speeds while limiting the top speed of the fan to a predetermined maximum level at higher engine speeds 7 22 ENGINE FAN DRIVE VISCOUS CLUTCH Continued On the 2 5L Diesel engine a viscous fan is stan dard 19307 31 Fig 8 Viscous Fan Drive Typical 1 VISCOUS FAN DRIVE 2 THERMOSTATIC SPRING 3 MOUNTING NUT TO WATER PUMP HUB OPERATION A thermostatic bimetallic spring coil is located on the front face of the viscous fan drive unit This spring coil reacts to the temperature of the radiator discharge air It engages the viscous fan drive for higher fan speed if the air temperature from the radiator rises above a c
92. EDURE 41 Install air filter assembly 42 Install engine cover Refer to 9 ENGINE COVER REMOVAL 43 Install engine oil fill cap 44 Fill cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 45 With assistance from another person install hood assembly on the vehicle 46 Connect under hood lamp on the hood assem bly 47 Connect negative battery cable INSTALLATION ENGINE COVER 1 Align engine cover with mounting bracket Push down firmly on all four corners of engine cover to snap in place Fig 2 2 Install oil dipstick tube 3 Install oil fill cap SPECIFICATIONS SPECIFICATIONS 2 8L COMMON RAIL DIESEL ENGINE ENGINE SPECIFICATIONS RPM 320Nm 32 6 kgm 2000 RPM 5 Bar Peak Torque Cylinder Compression Max Difference Between Cylinders Minimum Oil Pressure Warm 0 7 Bar Idle 2 Bar 3800 RPM CRANKSHAFT 62 985 63 005 mm 62 735 62 755 mm 63 045 63 074 mm 62 795 62 824 mm Clearance Between 0 040 0 089 mm Journal and Bearing 63 005 63 020 mm 62 755 62 770 mm 63 005 63 020 mm 62 755 62 770 mm Clearance Between 0 008 0 051 mm Journal and Bearing 89 980 90 000 mm 89 730 99 750 mm 90 045 90 065 mm 89 795 89 815 mm Clearance Between 0 045 0 080 mm Journal and Bearing 53 940 53 955 mm 53 690 53 705 mm 53 977 54 016 mm 53 727 53 766 mm Clearance Between 0 022 0 076 mm Journal and
93. EL LEAKS WITH A SHEET OF CARDBOARD WEAR SAFETY GOGGLES AND ADE QUATE PROTECTIVE CLOTHING WHEN SERVICING FUEL SYSTEM DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING AIR IN FUEL SYSTEM Air will enter the fue system whenever fuel supply lines separator filters injection pump high pressure lines or injectors are removed or disconnected Air trapped in the fuel system can result in hard start ing a rough running engine engine misfire low power excessive smoke and fue knock Inspect the fuel system from the fuel tank to the injectors for loose connections Refer to 14 FUEL SYSTEM WARNING Leaking fuel is an indicator of loose connections or defective seals Air can also enter the fuel system between the fuel tank and the fuel lift pump Inspect the fuel tank and fuel lines for damage that might allow air into the system With the DRBIII connected to the vehicle select Engine and the select Sensor Display Page down to view Fuel Pressure Set Point and Actual Fuel Pres sure Start the engine and observe the Fuel Pressure Set Point and the Actual Fuel Pressure If the Actual Fuel Pressure Oscillates above and below the Fuel Pressure Set Point in a regular cycle inspect the fuel system for air intrusion If the Actual Fuel Pressure gradually drops below the Fuel Pressure Set Point then spikes well above the Fuel Pressure Set Point replace the fuel pres sure solenoid Refer to 14 FUEL SYSTEM FUEL INJECTION FUEL PRESSURE SOL
94. ELT CHAIN COVER S INSTALLATION 19 Install engine in vehicle 20 Fill engine oil with proper oil to correct level CRANKSHAFT MAIN BEARINGS REMOVAL The engine must be removed from vehicle and com pletely disassembled to replace the front main bear ing CRANKSHAFT MAIN BEARINGS NOTE Identify the correct crankshaft by noting the smooth surface on the front of the 2 5L crankshaft and the groove on the front of the 2 8L crankshaft 1 With crankshaft assembly removed from engine 2 Remove crankshaft supports from crankshaft and remove bearing halves from supports Fig 30 ENGINE 9 31 80adf230 Fig 30 CRANKSHAFT ASSEMBLY CRANKSHAFT SUPPORT HALVE MAIN BEARING HALVE CRANKSHAFT MAIN BEARING HALVE CRANKSHAFT SUPPORT HALVE MAIN BEARING SUPPORT BOLTS WASHERS 9 32 ENGINE CRANKSHAFT MAIN BEARINGS Continued CRANKSHAFT FRONT MAIN BEARING 1 Using special tool 1073 push front main bearing out of front of engine block Fig 31 p 80 6 73 Fig 31 FRONT MAIN BEARING REMOVAL 1 VM 1073 2 FRONT CRANKSHAFT MAIN BEARING 3 ENGINE BLOCK INSTALLATION CRANKSHAFT MAIN BEARINGS NOTE Identify the correct crankshaft by noting the smooth surface on the front of the 2 5L crankshaft and the groove on the front of the 2 8L crankshaft 1 Install bearing halves in crankshaft supports 2 Lubricate cranksh
95. EM AND TURBOCHARGER KJ 7 Connect turbocharger oil return line at turbo charger Fig 13 8 Connect exhaust pipe at turbocharger down pipe 9 Lower vehicle from hoist 10 Connect oil supply line at turbocharger Fig 13 Torque banjo fitting to 24 5N m 11 Install exhaust manifold heat shield Fig 13 Torque retaining bolts to 27 5N m 12 Reposition EGR cooler and or EGR valve assembly on exhaust manifold Fig 12 Torque retaining nuts and bolt to 32 4N m 13 Connect EGR pipe to EGR valve Tighten bolts to 32 4N m 14 Connect EGR cooler coolant hoses at cooler 2 8L Fig 12 15 Install coolant recovery pressure container Refer to 7 COOLING ENGINE COOLANT RECOV ERY PRESS CONTAINER INSTALLATION 16 Refill cooling system Refer to 7 COOLING ENGINE STANDARD PROCEDURE 17 Connect charge air cooler inlet hose at turbo charger 18 Install air cleaner assembly Fig 11 19 Connect air inlet hose to turbocharger Fig 11 20 Install engine cover Refer to 9 ENGINE INSTALLATION 21 Connect negative battery cable KJ FUEL SYSTEM TABLE OF CONTENTS page FUEL SYSTEM 2 5L 2 8L TURBO DIESEL DESCRIPTION DIESEL FUEL DELIVERY SYSTEM WARNING HIGH FUEL SYSTEM PRESSURE 1 DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING AIR IN FUEL SYSTEM 1 DIAGNOSIS AND TESTING FUEL SUPPLY 5 2
96. ENOID REMOVAL 14 2 FUEL SYSTEM KJ FUEL SYSTEM 2 5L 2 8L TURBO DIESEL Continued DIAGNOSIS AND TESTING FUEL SUPPLY RESTRICTIONS LOW PRESSURE LINES Fuel supply line restrictions or a defective fuel lift pump can cause starting problems and prevent engine from accelerating The starting problems include low power and or white fog like exhaust Test all fuel supply lines for restrictions or block age induding the fuel filter Flush or replace as nec essar y HIGH PRESSURE LINES CAUTION High pressure lines cannot contact each other or other components Do not attempt to weld high pressure fuel lines or to repair lines that are damaged High pressure lines must be replaced at each disassembly Use only recommended lines when replacement of high pressure fuel line is nec essary Restricted kinked or bent high pressure lines can cause starting problems poor engine performance engine mis fire and white smoke from exhaust Refer to 14 FUEL SYSTEM WARNING STANDARD PROCEDURE STANDARD PROCEDURE PRIMING FUEL SYSTEM NOTE DO NOT force or pull up hard on the plunger when priming the fuel system Damage to the plunger or fuel filter water separate will result The fuel system must be primed if the fuel system has been serviced This is done using the fuel primer plunger located at the top of the fuel filter water sep arator 1 With service completed on the fuel system 2 Unscrew fuel system prime
97. Fig 28 CRANKSHAFT SUPPORT RETAINERS BALANCE SHAFT OIL FEED 1 CRANKSHAFT SUPPORT RETAINERS BALANCE SHAFT OIL FEED 2 O RINGS 3 3 ENGINE BLOCK 4 CRANKSHAFT SUPPORT RETAINER BALANCE SHAFT OIL FEED REMOVER INSTALLER VM 1054 80fefdat Fig 29 CRANKSHAFT SUPPORT RETAINERS BALANCE SHAFT OIL FEED ALIGNMENT PINS 1 ENGINE BLOCK 2 ALIGNMENT PINS VM 1079 CRANKSHAFT Continued 8 Install flywheel 9 Install piston and connecting rod assemblies Refer to 9 ENGINE ENGINE BLOCK PISTON amp CONNECTING ROD INSTALLATION 10 Install oil jets Refer to 9 ENGINE LUBRI CATION OIL INSTALLATION 11 Install balance shaft assembly Refer to 9 TIMING BALANCE SHAFT INSTALLATION 12 Install oil pump pickup tube Refer to 9 ENGINE LUBRICATION OIL PUMP INSTALLA TION 13 Install oil pan Refer to 9 ENGINE LUBRI CATION OIL PAN INSTALLATION 14 Install cylinder head Refer to 9 ENGINE CYLINDER HEAD INSTALLATION 15 Install cylinder head cover intake manifold Refer to 9 ENGINE CYLINDER HEAD CYLIN DER HEAD COVER S INSTALLATION 16 Install timing belt inner cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 17 Install timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION 18 Install timing belt outer cover Refer to 9 ENGINE VALVE TIMING TIMING B
98. G PERSONAL INJURY DEATH INSPECT FOR HIGH PRESSURE FUEL LEAKS WITH A SHEET OF CARDBOARD WEAR SAFETY FUEL DELIVERY 14 11 80 75963 Fig 11 VM 1067 INSTALLATION TIMING BELT INJECTION PUMP SPROCKET FLANGE OF VM 1067 INNER TIMING BELT COVER BOND GOGGLES AND ADEQUATE PROTECTIVE CLOTH ING WHEN SERVICING FUEL SYSTEM NOTE If Engine Timing Is Of Concern Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION or Refer to 9 ENGINE VALVE TIMING TMNG BELT CHAIN TENSIONER amp PULLEY ADJUSTMENTS 1 Loosen bolt in center of injection pump holding plate and slide high pressure injection pump through the accessory bracket into the injection pump sprocket 2 Install high pressure high pressure injection pump retaining nuts Fig 13 Torque nuts to 27 5N m 3 Unscrew injection pump holding plate part of VM 1067 from inner timing belt cover and remove Fig 12 4 Install high pressure injection pump sprocket retaining nut to hold sprocket in place 5 Remove flange and feet both part of VM 1067 from high pressure injection pump sprocket Fig 10 Fig 11 14 12 FUEL DELIVERY FUEL INJ ECTION PUMP Continued Y 80 7594 Fig 12 INJECTION PUMP GEAR REMOVAL USING VM 1067 1 TIMING BELT 2 INNER TIMING BELT COVER 3 INJECTION PUMP SPROCKET HOLDING PLATE ASSEMBLY PART OF VM 1067 4 INJECTION PUMP SPROCKET 6 Using special
99. GINE ENGINE BLOCK VIBRATION DAMPER INSTALLATION 9 Install cooling fan support Refer to 7 COOL ING ENGINE RADIATOR FAN INSTALLATION 10 Install accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 11 Install cooling fan and fan drive viscous clutch assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH INSTALLATION 12 Connect negative battery cable ENGINE COVER FRONT DESCRIPTION The front engine cover on this engine is a stamped steel cover which covers the oil pump and vacuum pump REMOVAL 1 Disconnect negative battery cable 2 Remove cooling fan and fan drive viscous clutch assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 3 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 4 Remove cooling fan support Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL 5 Remove vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER REMOVAL 6 Remove timing belt outer cover Refer to 9 TIMING TIMING BELT CHAIN COVER S REMOVAL 9 44 ENGINE ENGINE COVER FRONT Continued CAUTION Before removing the cylinder head cover intake manifold or timing belt the engine must put at 90 after TDC Failure to do so could result in valve and or piston damage during reassembly Refer to 9 ENGINE VALVE TIMING STANDARD PROCEDURE 7 Remove timi
100. GROUP LOCATOR Maintenance Schedules 7 Cooling 2 5L 2 8L Diesel Electronic Control Modules 8F Engine Systems Ignition Control 11 Exhaust System and Turbocharger 14 FuelSystem 21 Automatic Transmission 545RFE 25 Emissions Control 2 5L 2 8L Turbo Diesel Service Manual Comment Forms Rear of Manual KJ MAINTENANCE SCHEDULES 0 1 MAINTENANCE SCHEDULES TABLE OF CONTENTS page MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U S CANADA and MEXICO DESCRIPTION DIESEL ENGINES MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U S CANADA and MEXICO DESCRIPTION DIESEL ENGINES Maintenance Schedule Information not included in this section is located in the appropriate Owner s Manual There are two maintenance schedules that show the required service for your vehicle First is Schedule B It is for vehicles that are operated under the conditions that are listed below and at the beginning of the schedule e Extensive engine idling e Driving in dusty conditions e More than 50 of your driving is at sustained high speeds during hot weather above 32 C 90 F e Trailer towing e Taxi police or delivery service commercial ser vice NOTE Most vehicles are operated under the condi tions listed for Schedule B Second is Schedule A It is for vehicles that are not operated under any of the conditions listed under Schedule B Use the schedule that best de
101. H A SHEET OF CARDBOARD WEAR SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTH ING WHEN SERVICING FUEL SYSTEM High pressure fuel line leaks can cause starting problems and poor engine performance Start the engine Carefully move the cardboard over the high pressure fuel lines and check for fuel spray onto the cardboard Fig 7 If a high pressure line connection is leaking Replace damaged restricted or leaking high pressure fuel lines with the correct replacement line 8 19414 130 Fig 7 Typical Test for Leaks with Cardboard 1 HIGH PRESSURE LINE 2 CARDBOARD 3 FITTING CAUTION The high pressure fuel lines cannot con tact each other or other components Do not attempt to weld high pressure fuel lines or to repair lines that are damaged Only use the recommended lines when replacement of high pressure fuel line is necessary 14 10 FUEL DELIVERY FUEL INJ ECTION PUMP DESCRIPTION A radial piston pump is used as the high pressure pump for fuel pressure generation Refer to 14 FUEL SYSTEM WARNING Fig 8 80c4b5cd Fig 8 FUEL INJECTION PUMP 1 FUEL INJECTION PUMP 2 INJECTION PUMP PRESSURE SOLENOID REMOVAL WARNING HIGH PRESSURE LINES DELIVER DIE SEL FUEL UNDER EXTREME PRESSURE FROM THE INJECTION PUMP TO THE FUEL INJECTORS THIS MAY BE AS HIGH AS 1600BAR 23 200 PSI USE EXTREME CAUTION WHEN INSPECTING FOR HIGH PRESSURE FUEL LEAKS FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE SKIN
102. HE INJECTION PUMP TO THE FUEL INJECTORS THIS MAY BE AS HIGH AS 1600BAR 23 200PSI USE EXTREME CAUTION WHEN INSPECTING FOR HIGH PRESSURE FUEL LEAKS FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE SKIN CAUSING PERSONAL INJURY OR DEATH INSPECT FOR HIGH PRESSURE LEAKS WITH A SHEET OF CARDBOARD WEAR SAFETY GOG GLES AND ADEQUATE PROTECTIVE CLOTHING WHEN SERVICING FUEL SYSTEM 1 Disconnect negative battery cable 2 Remove engine cover Refer to 9 ENGINE REMOVAL 3 Disconnect injector electrical connector 4 Remove fuel return line from injector Fig 12 5 Remove fuel injector high pressure line Refer to 14 FUEL SYSTEM WARNING Fig 12 6 Remove fuel injector retainer and retaining bolt Fig 12 NOTE DO NOT use wire brush to clean the fuel injector or nozzle Possible restriction of the injec tor needle may result 7 Remove fuel injector from cylinder head Fig 12 INSTALLATION WARNING HIGH PRESSURE LINES DELIVER DIE SEL FUEL UNDER EXTREME PRESSURE FROM THE INJECTION PUMP TO THE FUEL INJECTORS THIS MAY BE AS HIGH AS 1600BAR 23 200 PSI USE EXTREME CAUTION WHEN INSPECTING FOR HIGH PRESSURE FUEL LEAKS FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE SKIN CAUSING PERSONAL INJURY OR DEATH INSPECT FOR HIGH PRESSURE FUEL LEAKS WITH A SHEET OF CARDBOARD WEAR SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTH ING WHEN SERVICING FUEL SYSTEM NOTE DO NOT use a brush to clean arou
103. ING NOTE Crankshaft hub retaining bolt has left hand 2 ENGINE BLOCK thread 3 SPECIAL TOOL VM 1073 2 Be sure oil hole in bearing lines up with oil gal lery in engine block Fig 34 71 lt DA 2 T a 3 4 80c6cad4 81068b41 Fig 34 FRONT MAIN BEARING ALIGNMENT Fig 35 FRONT ENGINE COVER 1 ENGINE BLOCK CRANKSHAFT HUB RETAINING BOLT 2 OIL HOLE IN BEARING FRONT COVER RETAINING BOLTS 3 FRONT CRANKSHAFT MAIN BEARING FRONT COVER ENGINE BLOCK FRONT ENGINE COVER ALIGNMENT DOWEL CRANKSHAFT HUB ORUN 3 Reassemble engine and install in vehicle 9 34 ENGINE KJ CRANKSHAFT OIL SEAL FRONT Continued 9 Remove crankshaft hub 10 Remove front engine cover Fig 35 Refer to 9 ENGINE ENGINE BLOCK ENGINE COVER REMOVAL 11 With cover on work bench pry out old seal INSTALLATION CAUTION Do Not use a hammer to install the crankshaft oil seal NOTE To prevent potential oil leaks DO NOT touch the front crankshaft inner seal Always handle the seal from the outer diameter 1 Clean engine block and front engine cover seal ing surfaces 2 Install crankshaft oil seal on VM 1061 Fig 36 3 Place sleeve for VM 1061 on pressbench as shown Fig 36 4 Position VM 1061 and press in new seal into front engine cover Fig 36 5 Install front engine cover on engine Refer to 9 ENGINE ENGINE BLOCK ENGINE CO
104. INJ ECTOR REMOVAL 32 Disconnect oil dip stick tube from intake man ifold 33 Disconnect brake booster line bracket from intake manifold and set aside 34 Remove fuel injectors Refer to 14 FUEL SYSTEM FUEL INJECTION FUEL INJECTOR REMOVAL CAUTION Before removing the cylinder head cover in take manifold or timing belt the engine must put at 90 after TDC Failure to do so could result in valve and or piston damage during reassembly Refer to 9 ENGINE VALVE TIMING STANDARD PROCEDURE 35 Remove timing belt outer cover Refer to 9 ENGINENALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 36 Remove timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL 37 Using VM 1055 remove both camshaft gears Fig 8 80c5f3ef Fig 8 CAMSHAFT GEAR REMOVAL INSTALLATION TIMING BELT INNER COVER CAMSHAFT SPROCKET IDLER PULLEYS CAMSHAFT SPROCKET VM 1055 CYLINDER HEAD Continued 38 Remove timing belt inner cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 39 Remove cylinder head cover intake manifold Refer to 9 ENGINE CYLINDER HEAD CYLIN DER HEAD COVER S REMOVAL 40 Remove rocker arm and lifter assemblies from cylinder head Be sure to keep in same order as removed 41 Remove cylinder head cover intake manifold gasket from cylinder head 42 Disconnect glow plug and engine coolant te
105. ION 1 22 REMOVAL 22 INSTALLATION 23 CYLINDER HEAD COVER DESCRIPTION _ 24 REMOVAL 24 INSTALLATION 24 ROCKER ARMS DESCRIPTION 26 OPERATION 26 REMOVAL 26 INSTALLATION 27 HYDRAULIC LIFTERS DESCRIPTION 27 REMOVAL 28 INSPECTION 28 INSTALLATION 28 ENGINE 9 1 page ENGINE BLOCK DESCRIPTION 28 CRANKSHAFT DESCRIPTION 28 OPERATION 527 28 STANDARD PROCEDURE CHECKING CRANKSHAFT END PLAY 28 REMOVAL pag eda 28 INSTALLATION 30 CRANKSHAFT MAIN BEARINGS REMOVAL RARE oda enc 31 INSTALLATION 32 CRANKSHAFT OIL SEAL FRONT REMOVAL ies ERI Pepe 33 INSTALLATION 34 CRANKSHAFT OIL SEAL REAR REMOVAL 35 INSTALLATION 35 CYLINDER LINERS DESCRIPTION iius isl RR IV 35 REMOVAL 2222 2 35 INSPECTION 36 INSTALLATION 36 PISTON amp CONNECTING ROD DESCRIPTION 4 884 37 STANDARD PROCEDURE PIS
106. IVE VISCOUS CLUTCH INSTALLATION 80 6 19 Fig 79 TIMING BELT TENSIONER ADJUSTMENT TIMING BELT IDLER PULLEY ENGINE FRONT COVER CRANKSHAFT HUB TIMING BELT TENSIONER TIMING BELT AUN 8 Install engine cover Refer to 9 ENGINE COVER INSTALLATION 9 Connect negative battery cable ADJ USTMENTS ADJUSTMENT TIMING BELT TENSIONER 1 With timing belt outer cover removed and tim ing belt installed 2 Loosen timing belt tensioner Fig 79 3 Align timing belt tensioner alignment pointer as shown and torque timing belt tensioner retaining bolt to 34 7N m Fig 80 8106b5f6 Fig 80 TIMING BELT TENSIONER ALIGNMENT 1 TENSIONER SPRING 2 1MM ALIGNMENT POINTER OVERLAP 3 TENSIONER ALIGNMENT POINTER 4 TENSIONER ASSEMBLY 4 Rotate engine 2 complete revolution and then recheck tensioner alignment Readjust tensioner alignment as necessary KJ EXHAUST SYSTEM AND TURBOCHARGER TABLE OF CONTENTS page EXHAUST SYSTEM AND TURBOCHARGER DESCRIPTION user ede eee dee eed ena X 1 SPECIFICATIONS TORQUE 2 EXHAUST PIPE REMOVAL usce nel Bete eel ae 2 INSTALLATION 2 MUFFLER REMOVAL p e EUR 2 INSTALLATION 3 HEAT SHIELDS DESCRIPTION Hea 4 CHARGE AIR COOLER AND PLUMBING REMOVAL REMOVAL CAC INLET HOSE 4 EXHAUST SYSTEM A
107. Install vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER INSTAL LATION 3 Install cooling fan support Refer to 7 COOL ING ENGINE RADIATOR FAN INSTALLATION 4 Install accessory drive belt Refer to 7 COOL ING ACCESSORY DRIVE DRIVE BELTS INSTAL LATION 5 Install cooling fan and fan drive viscous clutch assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH INSTALLATION 6 Install engine cover Refer to 9 ENGINE COVER INSTALLATION 7 Connect negative battery cable TIMING BELT IDLER PULLEY REMOVAL 1 Disconnect negative battery cable 2 Remove engine cover Refer to 9 ENGINE COVER REMOVAL 3 Remove cooling fan and fan drive viscous clutch assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 4 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 5 Remove cooling fan support Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL 6 Remove vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER REMOVAL 7 Remove timing belt outer cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 8 Remove timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL KJ TIMING BELT IDLER PULLEY Continued NOTE Idler pulley retaining bolts are left hand thread 9 Remove timing belt idler pulleys Fig 75 80ae1cd6
108. JURY OR DEATH INSPECT FOR HIGH PRESSURE LEAKS WITH A SHEET OF CARDBOARD WEAR SAFETY GOG GLES AND ADEQUATE PROTECTIVE CLOTHING WHEN SERVICING FUEL SYSTEM The fuel rail pressure sensor screws into the fuel rail at the top of the engine Fig 13 80cf1e6f Fig 13 SENSOR LOCATIONS 1 BOOST PRESSURE INTAKE AIR TEMPERATURE SENSOR 2 FUEL PRESSURE SENSOR FUEL PRESSURE SENSOR Continued OPERATION WARNING AVOID ALL CONTACT WITH FUEL SPRAY THE INJECTION PUMP SUPPLIES HIGH PRESSURE FUEL TO EACH INDIVIDUAL INJECTOR THROUGH HIGH PRESSURE LINES FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE SKIN AND CAUSE PERSONAL INJURY WEAR SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTHING WHEN SERVICING FUEL SYSTEM The fuel flows to the fuel pressure sensor through an opening in the rail the end of which is sealed off by the sensor diaphram Pressurized fuel reaches the sensor s diaphram through a blind hole The sensor element semiconductor device for converting the pressure to an electric signal is mounted on this dia phram The signal generated by the sensor is sent to the ECM REMOVAL 1 Disconnect negative battery cable 2 Remove engine cover Refer to 9 ENGINE COVER REMOVAL 3 Disconnect fuel pressure sensor electrical con nector Fig 13 4 Remove fuel pressure sensor from fuel rail Fig 13 FUEL INJECTION 14 25 INSTALLATION WARNING HIGH PRESSURE LINES DELIVER DIE SEL FUEL UNDER EX
109. KIM Once a key is learned to a SKIM it the key cannot be transferred to another vehicle If ignition key programming is unsuccessful the DRB 1119 will display one of the following messages Programming Not Attempted The DRB III attempts to read the programmed key status and there are no keys programmed into SKIM memory 8E 4 ELECTRONIC CONTROL MODULES ENGINE CONTROL MODULE Continued Programming Key Failed Possible Used Key From Wrong Vehicle SKIM is unable to program key due to one of the following e faulty ignition key transponder e ignition key is programmed to another vehicle 8 Keys Already Learned Programming Not Done SKIM transponder ID memory is full 5 Obtain ignition keys to be programmed from customer 8 keys maximum 6 Using the DRB 1119 erase all ignition keys by selecting MISCELLANEOUS and ERASE ALL CUR RENT IGN KEYS 7 Program all ignition keys Learned Key In Ignition Ignition key transponder ID is currently programmed SKIM memory REMOVAL 1 Disconnect negative battery cable 2 Disconnect ECM electrical connectors Fig 2 3 Remove ECM bracket to inner fender retaining nuts Fig 2 4 Remove ECM and bracket assembly from vehi cle Fig 2 5 Separate ECM from bracket INSTALLATION 1 Install ECM on bracket Fig 2 2 Position ECM and bracket assembly in vehicle Fig 2 3 Install ECM bracket to inner fender retaining nuts Fig 2 4 Connect
110. L 8 Connect vacuum line at EGR valve 9 Refill cooling system 10 Install engine cover KJ VALVE COOLER DESCRIPTION The EGR valve on the 2 8L engine uses a cooler to cool the exhaust gases before they return to the intake manifold Fig 2 The EGR cooler attaches to the EGR valve and is cooled with engine coolant 80cb44ee Fig 2 EGR VALVE COOLER AND COMPONENTS COOLANT HOSE HOSE RETAINER RETAINING BOLT EGR VALVE RETAINING NUTS EGR VALVE EGR VALVE GASKET HOSE CLAMP COOLANT HOSE HOSE CLAMP 0 COOLER TO EXHAUST MANIFOLD RETAINING BOLT 8 11 EGR COOLER 2 8L 12 EGR COOLER TO EGR VALVE RETAINING BOLTS 2 8L 13 EGR COOLER TO EGR VALVE GASKET 2 8L 14 HOSE CLAMP REMOVAL 1 Refer to 25 EMISSIONS CONTROL EXHAUST GAS RECIRCULATION VALVE REMOVAL INSTALLATION 1 Refer to 25 EMISSIONS CONTROL EXHAUST GAS RECIRCULATION VALVE INSTALLATION EXHAUST GAS RECIRCULATION 25 9 SOLENOID DESCRIPTION The EGR solenoid is mounted in the left rear of the engine compartment Fig 3 The EGR solenoid serves two different functions One is to control vac uum bleed off of the EGR valve The other is to con trol the on time of the EGR valve 80 4 Fig 3 EGR SOLENOID EGR SOLENOID VACUUM SUPPLY LINE EGR SOLENOID MOUNT EGR SOLENOID ELECTRICAL CONNECTOR EGR SOLENOID VACUUM LINE TO EGR VALV
111. L GLOW PLUG HARNESS CYLINDER LINER CYLINDER BLOCK CYLINDER HEAD GASKET CYLINDER HEAD 0 ROCKER ARM ASSEMBLIES INSTALLATION 1 Install coolant temperature sensor in cylinder head Fig 5 2 Connect coolant temperature sensor electrical connector Fig 5 3 Refill cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 4 Connect negative battery cable ENGINE COOLANT THERMOSTAT DESCRIPTION pellet type thermostat controls the operating temperature of the engine by controlling the amount of coolant flow to the radiator Fig 6 OPERATION The thermostat starts to open at 80 C 176 F Above this temperature coolant is allowed to flow to the radiator This provides quicker engine warmup and overall temperature control The same thermostat is used for winter and sum mer seasons An engine should not be operated with out a thermostat except for servicing or testing Operating without a thermostat causes other prob lems These are longer engine warmup time unreli able warmup performance increased exhaust emissions and crankcase condensation This conden sation can result in sludge formation REMOVAL NOTE The thermostat is not serviced separately The thermostat and housing must be replaced as an assembly 1 Disconnect negative battery cable 2 Remove engine cover Refer to 9 ENGINE COVER REMOVAL 3 Partially drai
112. MATIC TRANSMISSION 545RFE 21 35 INPUT CLUTCH HUB O RING SEALS SEAL SNAP RING SNAP RING UD BALANCE PISTON SNAP RING UD PISTON SPRING 0 DISC 808a2e66 Fig 12 Input Clutch Assembly Part 1 11 12 13 14 15 16 17 18 19 20 UD CLUTCH PLATE CLUTCH RETAINER SEAL OD REV PISTON BELLEVILLE SPRING SNAP RING SEAL RINGS INPUT SHAFT LUBRICATION CHECK VALVE AND SNAP RING 21 36 AUTOMATIC TRANSMISSION 545RFE INPUT CLUTCH ASSEMBLY Continued ASSEMBLY 1 Install all new seals and o rings onto the input shaft and input hub The o rings on the input hub are color coded Be sure to install the correct o ring in the correct location 2 Check the transmission lubrication check valve located in the input shaft using shop air The valve should only allow air flow in one direction If the valve allows no air flow or air flow in both direc tions the valve will need to be replaced KJ 3 Lubricate all seals with Mopar ATF 4 Auto matic Transmission Fluid prior to installation 4 Assemble the OD reverse piston onto the input clutch hub Fig 13 5 Assemble the input clutch retainer onto the input clutch hub Install the input dutch retainer tapered snap ring with tapered side up onto the input clutch hub 808a2e66 Fig 13 Input Clutch Assembly Part 1 INPUT CLUTCH HUB 2 O RING SEALS 3 SEAL 4 SNAP RING 5 SNAP RING
113. ND TURBOCHARGER DESCRIPTION The basic exhaust system consists of an engine exhaust manifold turbocharger exhaust down pipe exhaust pipe exhaust heat shield s muffler and exhaust tailpipe The exhaust system uses a single muffler The exhaust system must be properly aligned to prevent stress leakage and body contact If the sys tem contacts any body panel it will transfer objec tionable noises originating from the engine to the body EXHAUST SYSTEM AND TURBOCHARGER 11 1 page REMOVAL CAC OUTLET HOSE 4 INSTALLATION INSTALLATION CAC INLET HOSE 4 INSTALLATION CAC OUTLET HOSE 4 TURBOCHARGER DESCRIPTION E EP 5 OPERATION galas 5 REMOVAL Ed ehe 7 CLEANING bea wages 8 INSTALLATION cee ae de Re ee Gees 9 When inspecting an exhaust system critically inspect for cracked or loose joints stripped screw or bolt threads corrosion damage and worn cracked or broken hangers Replace all components that are badly corroded or damaged DO NOT attempt to repair When replacement is required use original equip ment parts or equivalent This will assure proper alignment and provide acceptable exhaust noise els CAUTION Avoid application of rust prevention com pounds or undercoating materials to exhaust sys tem floor pan exhaust heat shields Light overspray near the edges is permitted Application of
114. NOTE Remove oil jets before removing piston crankshaft liners 1 Disconnect negative battery cable 2 Raise vehicle on hoist 3 Remove oil pan Refer to 9 ENGINE LUBRI CATION OIL PAN REMOVAL 4 Using special tool 1060 to hold oil jet Remove oil jet retaining bolt and remove oil jet from engine block Fig 67 ION Fig 67 OIL JET REMOVAL INSTALLATION SPECIAL TOOL VM 1060 OIL JET CONNECTING ROD CRANKSHAFT 80c6cbd9 9 50 ENGINE OIL J ET Continued INSTALLATION CAUTION Use caution when removing and installa ing oil jets Damage to oil jet nozzle could cause severe engine damage NOTE Carefully install the oil jets After assembling the engine liners crankshaft and pistons 1 Lubricate o ring on oil jet 2 Using special tool VM 1060 install oil jet in engine block Fig 67 3 Install oil jet retaining bolt Torque bolt to 10 8N m 4 Install oil pan Refer to 9 ENGINE LUBRI CATION OIL PAN INSTALLATION 5 Refill engine oil to proper level 6 Connect negative battery cable INTAKE MANIFOLD DESCRIPTION Refer to 9 ENGINE CYLINDER HEAD CYLIN DER HEAD COVER S DESCRIPTION REMOVAL 1 Refer to 9 ENGINE CYLINDER HEAD CYL INDER HEAD COVER S REMOVAL INSTALLATION 1 Refer to 9 ENGINE CYLINDER HEAD CYL INDER HEAD COVER S INSTALLATION EXHAUST MANIFOLD REMOVAL 1 Refer to
115. NSTALLATION 21 Install brake booster line bracket to intake manifold 22 Install oil dip stick tube to intake manifold 23 Connect fuel pump high pressure line to fuel rail 24 Install fuel injector pressure lines 25 Connect fuel return hose to fuel injectors 26 Connect engine coolant hoses to thermostat housing 27 Raise vehide 28 Reconnect exhaust system bracket at trans mission crossmember 29 Connect exhaust stabilizer bracket to lower exhaust manifold Fig 11 30 Install turbocharger oil feed line to turbo charger 31 Lower vehicle ENGINE 9 21 32 Install turbocharger heat shield 33 Install exhaust manifold heat shield 34 Install EGR cooler assembly and connect engine coolant hoses 35 Install air cleaner housing 36 Install main engine wiring harness and con nect all ancillary electrical components 37 Install throttle cable assembly 38 Install viscous heater 39 Install vibration damper 40 Install generator Refer to 8 ELECTRICAL CHARGING GENERATOR INSTALLATION 41 Install cooling fan support Refer to 7 COOLING ENGINE RADIATOR FAN INSTALLA TION 42 Install front engine lift bracket 43 Install power steering pump pulley 44 Install accessory drive belt tensioner and both idler pulleys Idler pulley retaining bolts are L H Thread 45 Install accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATI
116. OCK RETAINING BOLT FUEL RETURN JUNCTION BLOCK KJ FUEL TANK MODULE DESCRIPTION The fuel pump module assembly is located in the fuel tank The assembly is divided into 2 sections upper and lower The lower section is locked to the bottom of the fuel tank The complete assembly con tains the following components e A separate fuel pick up or inlet filter A lockring to retain upper section of pump mod ule to tank e A rollover valve e A soft gasket between tank flange and module e A fuel gauge sending unit fuel level sensor e Two fuel line connections supply and return The fuel gauge sending unit may be serviced sepa rately REMOVAL Fuel tank removal is not required for fuel tank module removal Access is from rear cargo area 1 Disconnect negative battery cable 2 Four cargo holdown clamps are located inside the vehicle on the floor of the rear cargo area Remove the 2 rearward mounted clamps by drilling out the clamp rivets 3 Fold carpeting forward to gain access to fuel tank module access plate Fig 14 4 Remove 4 fuel pump module access plate nuts Fig 14 5 While applying heat with a heat gun carefully pry up the fuel tank module access plate Take care not to bend plate 6 Thoroughly clean area around top of tank mod ule to prevent contaminants from entering fuel tank or lines 7 Disconnect fuel supply and return lines at fuel tank module by pressing 2 buttons at sides of fit
117. OIL PRESSURE RELIEF VALVE INSTALLATION 1 VM 1059 2 OIL PRESSURE RELIEF VALVE 3 ENGINE BLOCK 4 OIL PUMP OIL PRESSURE SENSOR SWITCH DESCRIPTION The oil pressure switch is located on the right side of the engine block The switch screws into the engines main oil gallery OPERATION The oil pressure sensor uses three circuits They are e A signal circuit to the ECM e A sensor ground circuit through the ECM e A 5 volt reference circuit from the ECM The oil pressure sensor returns a voltage signal back to the ECM relating oil pressure Ground for the sensor is supplied by the ECM OIL PUMP REMOVAL REMOVAL OIL PUMP PICKUP TUBE 1 Disconnect negative battery cable 2 Raise vehicle on hoist 9 48 ENGINE OIL PUMP Continued 3 Remove oil pan Refer to 9 ENGINE LUBRI CATION OIL PAN REMOVAL 4 Remove oil pump pickup tube retaining bolt and pull pickup tube from engine block Fig 64 8043586 Fig 64 OIL PUMP PICKUP TUBE ASSEMBLY BALANCE SHAFT OIL JET RETAINING BOLT OIL JET ENGINE BLOCK CRANKSHAFT O RING S BALANCE SHAFT RETAINING BOLTS OIL DIPSTICK TUBE RETAINER RUBBER BUSHING 1 2 3 4 5 6 7 8 9 10 RETAINING BOLT REMOVAL OIL PUMP 1 Disconnect negative battery cable 2 Remove cooling fan and fan drive viscous clutch assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 3 Remove accessory drive be
118. OLANT THERMO STAT REMOVAL 21 Remove exhaust manifold retaining nuts and remove exhaust manifold and turbocharger assembly from vehicle Fig 13 22 Remove turbocharger to exhaust manifold retaining nuts and separate turbocharger from exhaust manifold Fig 14 CLEANING All old gaskets should be inspected for any tears or signs of prior leakage If any gaskets show such indi cations they should be replaced with new gaskets All gasket mating surfaces must be cleaned of old gasket material to produce a smooth and dirt free sealing surface for the new gasket TURBOCHARGER Continued 80cb44ee Fig 12 EGR VALVE COOLER AND COMPONENTS COOLANT HOSE HOSE RETAINER RETAINING BOLT EGR VALVE RETAINING NUTS EGR VALVE EGR VALVE GASKET HOSE CLAMP COOLANT HOSE HOSE CLAMP 0 COOLER EXHAUST MANIFOLD RETAINING BOLT 8 11 EGR COOLER 2 8L 12 EGR COOLER TO EGR VALVE RETAINING BOLTS 2 8L 13 EGR COOLER TO EGR VALVE GASKET 2 8L 14 HOSE CLAMP INSTALLATION 1 Connect turbocharger to exhaust manifold with new gasket Fig 14 Torque retaining nuts to 32 4N m NOTE After Tightening The Exhaust Manifold To Specification Using Diagonal Cross Pattern Retrace The Pattern Checking The Correct Torque Value Again 2 Install exhaust manifold and turbocharger assembly with new gasket in position on studs in inder head Fig 13 In
119. ON 46 Install cooling fan and fan drive viscous clutch assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH INSTALLATION 47 Install upper radiator core support 48 Refill cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 49 Install engine cover and bracket Refer to 9 ENGINE COVER INSTALLATION 50 Connect negative battery cable 51 Start engine and inspect for leaks Refer to 14 FUEL SYSTEM WARNING CAMSHAFT OIL SEAL S REMOVAL 1 Disconnect negative battery cable 2 Remove cooling fan and fan drive viscous clutch assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 3 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 4 Remove fan support Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL 5 Remove vibration damper 6 Remove outer timing belt cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 9 22 ENGINE CAMSHAFT OIL SEAL S Continued WARNING Before removing the timing belt the engine musi put at 90 after TDC Failure to do so could result in valve and or piston damage during reassembly Refer to 9 ENGINE VALVE TIMING STANDARD PROCEDURE 7 Remove timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL 8 Using VM 1055 remove both camshaft gears Fig 13 80c5f3ef Fig 13 CAMSHAFT GEAR REMOV
120. PERSONAL INJURY DEATH INSPECT FOR HIGH PRESSURE FUEL LEAKS WITH A SHEET OF CARDBOARD WEAR SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTH ING WHEN SERVICING FUEL SYSTEM NOTE High Pressure Fuel Lines To Injectors Must Be Replaced At Each Disassembly CAUTION The high pressure fuel lines cannot con tact each other or other components Do not attempt to weld high pressure fuel lines or to repair lines that are damaged If lines are ever kinked or bent they must be replaced Use only the recom mended lines when replacement of high pressure fuel line is necessary High pressure fuel lines deliver fuel under extremely high pressure from the high pressure pump to the fuel injectors Refer to 14 FUEL SYS TEM WARNING The lines expand and contract from the high pressure fuel pulses generated during the injection process All high pressure fuel lines are of the same length and inside diameter Correct high pressure fuel line usage and installation is critical to smooth engine operation FUEL DELIVERY 14 9 DIAGNOSIS AND TESTING HIGH PRESSURE FUEL LINES WARNING HIGH PRESSURE LINES DELIVER DIE SEL FUEL UNDER EXTREME PRESSURE FROM THE INJECTION PUMP TO THE FUEL INJECTORS THIS MAY BE AS HIGH AS 1600BAR 23 200 PSI USE EXTREME CAUTION WHEN INSPECTING FOR HIGH PRESSURE FUEL LEAKS FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE SKIN CAUSING PERSONAL INJURY DEATH INSPECT FOR HIGH PRESSURE FUEL LEAKS WIT
121. RFE AUTOMATIC TRANSMISSION 545RFE Continued 21 20 HLYNOA NI MO TH 62690808 NO99 330959 3 1 isdsaunssaua 08 21 8S8 591 96 ACA 4 2 dL FY 249944 14 MO THH3AO 041 413 5 HOSN3S S3Hd 3NI1 Sd1 105 1OH1NOO 6 4 594 108135 1101 1 511 HOLIMS 4 54 563 14 19 H31H3ANOO 20 HOLNTO 10 28 5 3AIHQH3AO QO 19 22 3Su3A3H MOT H1 vo 8 0 TN 2 8 1 04 COOLER gt 2ooc 21 21 AUTOMATIC TRANSMISSION 545RFE AUTOMATIC TRANSMISSION 545RFE Continued 78590208 IOWA Wduoosviy 59 340 55 3NH isasaunssaud 28 51 8 96 5916 22222222 ld 4 HOSN3S Saud 1 5 1 419374S ILINN SW H31HJANOO ODO M 1 19 6 2 2 1 106 10H1NOO SSHd SOd INDY ars era Q31VA3 137 HOLIMS SdHd Sd P 3905539 1 1D J3SH3A3H OH 3SuaAdd MO H 1
122. RING SUPPORT O RING O RING ALIGNMENT DOWEL CRANKSHAFT RELUCTOR WHEEL RELUCTOR WHEEL RETAINING BOLTS REAR MAIN BEARING SUPPORT RETAINING BOLTS TRANSMISSION ADAPTER PLATE BOLT DIAL INDICATOR FLEXPLATE ADAPTER FLEXPLATE ADAPTER RETAINING BOLTS 18 ALIGNMENT DOWEL cilii cx Che lE lk O 3 Drain engine oil and remove oil filter 4 Remove timing belt outer cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 5 Remove timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL ENGINE 9 29 6 Remove timing belt inner cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 7 Remove cylinder head cover intake manifold Refer to 9 ENGINE CYLINDER HEAD CYLIN DER HEAD COVER S REMOVAL 8 Remove cylinder head Refer to 9 ENGINE CYLINDER HEAD REMOVAL 9 Remove flywheel 10 Remove rear main bearing support adapter plate retaining bolts and remove adapter plate Fig 26 11 Remove rear main bearing support by thread ing two retaining bolts in holes provided Tighten bolts equally to push main bearing support out of block Fig 26 80c6ea3e Fig 26 REAR MAIN BEARING SUPPORT REMOVAL 1 BOLTS 2 REAR MAIN BEARING SUPPORT 3 CRANKSHAFT 12 Remove front engine cover Refer to 9 ENGINE ENGINE BLOCK ENGINE COVER REMOVAL 1
123. ROCEDURE Disconnect the radiator upper hose from the radiator and attach the flushing gun to the hose Disconnect the radiator lower hose from the water pump Attach a lead away hose to the water pump inlet fitting CAUTION Be sure that the heater control valve is closed heat off This is done to prevent coolant flow with scale and other deposits from entering the heater core Connect the water supply hose and air supply hose to the flushing gun Allow the engine to fill with water When the engine is filled apply air in short blasts allowing the system to fill between air blasts Continue until clean water flows through the lead away hose For more information refer to operating instructions supplied with flushing equipment Remove the lead away hose flushing gun water supply hose and air supply hose Remove the thermo stat housing Refer to 7 COOLING ENGINE EN GINE COOLANT THERMOSTAT REMOVAL Install the thermostat and housing with a replace ment gasket Refer to 7 COOLING ENGINE EN GINE COOLANT THERMOSTAT INSTALLATION Connect the radiator hoses Refill the cooling system with the correct antifreeze water mixture Refer to 7 COOLING STANDARD PRO CEDURE CLEANING Drain cooling system and refill with clean water Refer to procedures in this section Run engine with pressure vent cap installed until upper radiator hose is hot Stop engine and drain water from system If water is dirty fill run and drai
124. RY DRIVE BELT DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION RIB CHUNKING One or more ribs has separated from belt body 1 Foreign objects imbedded in pulley grooves 2 Installation damage 1 Remove foreign objects from pulley grooves Replace belt 2 Replace belt RIB OR BELT WEAR 1 Pulley misaligned 2 Abrasive environment 3 Rusted pulley s 4 Sharp or jagged pulley groove tips 5 Belt rubber deteriorated 1 Align pulley s 2 Clean pulley s Replace belt if necessary 3 Clean rust from pulley s 4 Replace pulley Inspect belt 5 Replace belt BELT SLIPS 1 Belt slipping because of insufficient tension 2 Belt or pulley exposed to substance that has reduced friction belt dressing oil ethylene glycol 3 Driven component bearing failure seizure 4 Belt glazed or hardened from heat and excessive slippage 1 Inspect Replace tensioner if necessary 2 Replace belt and clean pulleys 3 Replace faulty component or bearing 4 Replace belt LONGITUDAL BELT CRACKING GROOVE JUMPING Belt does not maintain correct position on pulley 1 Belt has mistracked from pulley groove 2 Pulley groove tip has worn away rubber to tensile member 1 Incorrect belt tension 2 Pulley s not within design tolerance 3 Foreign object s in grooves 4 Pulley misalignment 5 Belt cordline is broken 1 Replace belt 2 Replace belt 1 Inspect Rep
125. Remove accessory drive belt from the engine Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 25 Accessing bolts through the pump pulley remove power steering pump retaining bolts and position pump aside with lines still attached 26 Remove engine cover mounting bracket retaining bolts and remove the bracket from the top of the engine 27 Disconnect four large electrical connectors near the rear of the right front fenderwell 28 Disconnect heater core inlet and outlet hoses from the heater core 29 Remove generator from engine Refer to 8 ELECTRICAL CHARGING GENERATOR REMOV AL This will provide access to the wires beneath it 30 Remove low side refrigerant line retaining nuts from accumulator and compressor and remove from engine bay 31 Trace engine wiring and disconnect electrical connectors and tie straps one at a time untill all wir ing is disconnected from the engine assembly When all the engine electrical harness is disconnected fold the harness over the left front fenderwell 32 Remove coolant elbow retaining bolts from rear of the water pump 33 Disconnect coolant hoses leading from the coolant elbow and remove coolant elbow from engine 34 Remove oil cooler adapter 35 Raise and support the vehicle 36 Remove oil filter and adaptor assemby 37 Remove starter motor from engine Refer to 8 ELECTRICAL STARTING STARTER MOTOR REMOVAL 38 Remove chassis ground wire above
126. Remove crankshaft hub 10 Remove front engine cover Refer to 9 BLOCK ENGINE COVER REMOVAL 11 Remove crankshaft sprocket Fig 56 12 Remove vacuum pump Fig 56 INSTALLATION NOTE Verify the 3 blades on the vacuum pump are in place and correctly assembled The tapered edge should be on the outer side Make sure the pump rotates before installation 1 Lubricate vacuum pump components and install in engine block Fig 57 Torque bolts to 10 8N m 2 Install crankshaft sprocket Torque bolts to 10 8N m INTERNAL VACUUM PUMP Continued 80 9048 Fig 56 OIL PUMP AND VACUUM PUMP VACUUM PUMP CRANKSHAFT SPROCKET OIL PUMP ENGINE BLOCK CRANKSHAFT AUN 80 07 7 Fig 57 VACUUM PUMP COMPONENTS 1 VACUUM PUMP BODY 2 VACUUM PUMP BLADE TAPERED EDGE 3 VACUUM PUMP BLADE ENGINE 9 43 3 Install front engine cover Refer to 9 ENGINE ENGINE BLOCK ENGINE COVER INSTALLATION 4 Install front crankshaft hub Torque bolt to 304N m 5 Install timing belt inner cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 6 Install timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION 7 Install timing belt outer cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 8 Install vibration damper crankshaft pulley Refer to 9 EN
127. Remove turbocharger oil feed line from turbo charger Fig 9 23 Raise and support vehicle 24 Disconnect exhaust stabilizer bracket at lower exhaust manifold Fig 9 25 Disconnect exhaust system bracket at trans mission crossmember 26 Lower the vehicle and remove the exhaust manifold retaining nuts 27 Slide the exhaust manifold and turbocharger off of exhaust manifold studs Fig 9 28 Remove coolant hoses at thermostat housing 9 18 ENGINE CYLINDER HEAD Continued 8105d55a Fig 7 THERMOSTAT HOUSING THERMOSTAT HOUSING GASKET THERMOSTAT HOUSING TURBOCHARGER OIL SUPPLY LINE BANJO BOLT THERMOSTAT HOUSING RETAINING BOLTS BRASS WASHER EXHAUST MANIFOLD GASKET EXHAUST MANIFOLD EXHAUST MANIFOLD HEATSHIELD EXHAUST MANIFOLD HEATSHIELD RETAINING BOLTS OIL RETURN HOSE HOSE CLAMPS EXHAUST MANIFOLD RETAINING NUTS TURBOCHARGER DOWNPIPE STUDS TURBOCHARGER DOWN PIPE GASKET TURBOCHARGER DOWNPIPE TURBOCHARGER DOWNPIPE RETAINING NUT ak mE 3 29 Disconnect fuel return hose from fuel injectors and set aside Refer to 14 FUEL SYSTEM FUEL ECTION FUEL INJ ECTOR REMOVAL 30 Remove fuel injector pressure lines Refer to 14 FUEL SYSTEM FUEL ECTION FUEL ECTOR REMOVAL KJ 31 Disconnect fuel pump high pressure line at fuel rail Refer to 14 FUEL SYSTEM FUEL EC TION FUEL
128. SEMBLY Continued 27 Remove the reverse clutch pack from the input clutch retainer 28 Install the number 2 bearing onto the under drive hub with outer race against the hub with petro leum jelly 29 Install the underdrive hub into the input clutch retainer 30 Install the number 3 bearing into the over drive hub with the outer race against the hub with petroleum jelly 31 Install the overdrive hub into the input clutch retainer 32 Install the number 4 bearing into the reverse hub with outer race against the hub with petroleum jelly 33 Install the reverse hub into the input dutch retainer 34 Install the complete reverse clutch pack 35 Install the reverse reaction plate and snap ring 36 Push up on reaction plate to allow reverse clutch to move freely SHIFT MECHANISM DESCRIPTION The gear shift mechanism provides six shift posi tions which are e Park P e Reverse R e Neutral N e Drive D e Manual second 2 e Manual low 1 OPERATION MANUAL LOW 1 range provides FIRST gear only Overrun braking is also provided in this range MANUAL SECOND 2 range provides FIRST and SECOND gear only DRIVE range provides FIRST SECOND THIRD and OVERDRIVE FOURTH and FIFTH gear ranges The shift into OVERDRIVE FOURTH and FIFTH gear range occurs only after the transmission has completed the shift into D THIRD gear range No further movement of the shift mechanism is required to complete th
129. SMISSION 545RFE DESCRIPTION The 545RFE automatic transmission is a sophisti cated multi range electronically controlled transmis sion which combines optimized gear ratios for responsive performance state of the art efficiency features and low NVH Other features indude driver adaptive shifting and three planetary gear sets to provide wide ratio capability with precise ratio steps for optimum driveability The three planetary gear sets also make available a unique alternate second gear ratio The primary 2nd gear ratio fits between 1st and 3rd gears for normal through gear accelera tions The alternate second gear ratio 2prime allows AUTOMATIC TRANSMISSION 545RFE 21 1 page OPERATION RR RE 30 DISASSEMBLY idisse ERR 33 ASSEMBLY wee 36 SHIFT MECHANISM DESCRIPTION 40 OPERATION 40 SOLENOID SWITCH VALVE DESGRIPTION nk ean bee e s 40 OPERATION Oy eee 40 TORQUE CONVERTER OPERATION 40 TRANSMISSION SOLENOID TRS ASSEMBLY DESCRIPTION 42 OPERATION 222522454 42 REMOVAL 43 INSTALLATION 43 VALVE BODY DESCRIPTION 2 222 22225 24 43 OPERATION 44 smoother 4 2 kickdowns at high speeds to provide 2nd gear passing performance over a wider high
130. SSORY DRIVE DRIVE BELTS INSTAL LATION 3 Connect negative battery cable 80d39d51 Fig 8 VIBRATION DAMPER AND IDLER PULLEY 1 VIBRATION DAMPER CRANKSHAFT PULLEY RETAINING BOLTS 2 VIBRATION DAMPER CRANKSHAFT PULLEY 3 IDLER PULLEY 7 16 ENGINE KJ ENGINE TABLE OF CONTENTS page page COOLANT OPERATION 20 STANDARD PROCEDURE REMOVAL 52266 x E Au deen 20 STANDARD PROCEDURE DRAINING INSTALLATION 21 COOLING SYSTEM 16 FAN DRIVE VISCOUS CLUTCH STANDARD PROCEDURE COOLING DESCRIPTION 72255055 aenea tes 21 SYSTEM FILLING 17 OPERATION I Ee oo eens 22 STANDARD PROCEDURE REFILLING DIAGNOSIS AND TESTING FAN DRIVE COOLING SYSTEM 17 VISCOUS 22 COOLANT RECOVERY PRESS CONTAINER REMOVAL setius ud duet Edu nius 22 DESGRIPTION Awad e 17 INSTALLATION 23 OPERATION cede 17 RADIATOR COOLING FAN REMOVAL 5894500 bade be 23 REMOVAL INSTALLATION 24 REMOVAL COOLING FAN 17 WATER PUMP REMOVAL COOLING FAN SUPPORT 17 DESCRIPTION 24 CLEANING 17 OPERATION 24 INSPEGTION ug 17 REMOVAL WATER PUMP 24 INSTALLATION CLEANING
131. STALLATION 4 Refill cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 5 Connect negative battery cable RADIATOR PRESSURE CAP DESCRIPTION The cooling system pressure cap is located on the coolant recovery pressure container The cap con struction includes stainless steel swivel top rubber seals and retainer main spring and a spring loaded valve Fig 12 9207 12 6 Fig 12 Cooling System Pressure Cap Filler Neck OVERFLOW NIPPLE MAIN SPRING GASKET RETAINER STAINLESS STEEL SWIVEL TOP RUBBER SEALS VENT VALVE PRESSURE BOTTLE FILLER NECK OPERATION The cooling system is equipped with a pressure cap that releases excessive pressure maintaining a range of 97 124 kPa 14 18 psi The cooling system will operate at higher than atmospheric pressure The higher pressure raises the coolant boiling point thus allowing increased radia tor cooling capacity There is also a vent valve in the center of the cap This valve also opens when coolant is cooling and contracting allowing the coolant to return to cooling system from coolant reserve system tank by vacuum ENGINE 7 25 through connecting hose If valve is stuck shut or the coolant recovery hose is pinched the radiator hoses will be collapsed on cool down Clean the vent valve Fig 12 and inspect cool ant recovery hose routing to ensure proper sealing when boiling point is re
132. T HOUSING 1 THERMOSTAT HOUSING GASKET 2 THERMOSTAT HOUSING 3 TURBOCHARGER OIL SUPPLY LINE BANJO BOLT 4 THERMOSTAT HOUSING RETAINING BOLTS 5 BRASS WASHER 6 EXHAUST MANIFOLD GASKET 7 EXHAUST MANIFOLD 8 EXHAUST MANIFOLD HEATSHIELD 9 EXHAUST MANIFOLD HEATSHIELD RETAINING BOLTS 10 OIL RETURN HOSE 11 HOSE CLAMPS 12 EXHAUST MANIFOLD RETAINING NUTS 13 TURBOCHARGER DOWNPIPE STUDS 14 TURBOCHARGER DOWN PIPE GASKET 15 TURBOCHARGER DOWNPIPE 16 TURBOCHARGER DOWNPIPE RETAINING NUT 14 Install timing belt inner cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 15 Using VM 1055 install both camshaft gears and tighten bolts finger tight 16 Install timing belt Refer to 9 ENGINE VALVE BELT CHAIN AND SPROCKETS INSTALLATION CYLINDER HEAD Continued 17 Using VM 1055 torque cam gear retaining bolts to 108 N m Fig 12 80c5f3ef Fig 12 CAMSHAFT GEAR REMOVAL INSTALLATION TIMING BELT INNER COVER CAMSHAFT SPROCKET IDLER PULLEYS CAMSHAFT SPROCKET 1055 akon 18 Install timing belt outer cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 19 Remove crankshaft and both camshaft locking pins at this time Refer to 9 ENGINE VALVE TIMING STANDARD PROCEDURE 20 Install fuel injectors Refer to 14 FUEL SYS TEM FUEL INJ ECTION FUEL INJECTOR I
133. TALLATION 13 Refill cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 14 Connect negative battery cable HYDRAULIC LIFTERS DESCRIPTION Valve lash is controlled by hydraulic tappets located inside the cylinder head in tappet bores below the camshafts Fig 22 804368 5 Fig 22 CYLINDER HEAD ASSEMBLY CYLINDER HEAD BOLT GLOW PLUG COOLANT TEMPERATURE SENSOR CYLINDER HEAD ALIGNMENT DOWEL GLOW PLUG HARNESS CYLINDER LINER CYLINDER BLOCK CYLINDER HEAD GASKET CYLINDER HEAD 0 ROCKER ARM ASSEMBLIES S 9 28 ENGINE HYDRAULIC LIFTERS Continued REMOVAL 1 Refer to 9 ENGINE CYLINDER HEAD ROCKER ARM ADJ USTER ASSY REMOVAL INSPECTION Clean each lifter assembly in cleaning solvent to remove all varnish and sludge deposits Inspect for indications of scuffing on the side and base of each lifter body INSTALLATION 1 Refer to 9 ENGINE CYLINDER HEAD ROCKER ARM ADJUSTER ASSY INSTALLA TION ENGINE BLOCK DESCRIPTION The 2 5L 2 8L CRD Diesel engine uses a cast iron engine block with wet cast iron cylinder liners Fig 23 80c6aef8 Fig 23 ENGINE BLOCK CRANKSHAFT DESCRIPTION The crankshaft for the 2 5L and the 2 8L is a forged steel type design with five main bearing jour nals The crankshaft is located at the bottom of the engine block and is held in place with three main be
134. TANK MODULE REMOVAL 2 To remove sending unit from tank module lift on plastic locking tab Fig 18 while sliding sending unit upwards 3 Disconnect electrical connector from bottom of upper secion of fuel tank module Separate neces sary sending unit wiring 80cc6d01 Fig 18 FUEL LEVEL SENDING UNIT 1 LIFT TAB HERE FOR REMOVAL 2 FUEL LEVEL SENDING UNIT 3 LOWER SECTION OF PUMP MODULE INSTALLATION 1 Connect necessary wiring into electrical con nectors 2 Position sending unit to tank module Slide and snap into place 3 Install lower section of fuel tank module Refer to 14 FUEL SYSTEM FUEL DELIVERY FUEL TANK MODULE INSTALLATION 14 16 FUEL DELIVERY FUEL HEATER DESCRIPTION The fuel heater is used to prevent diesel fuel from waxing and plugging the fuel filter during cold weather operation The fuel heater is located in the fuel filter of the fuel filter water separator assembly Fig 19 iU 2 1 7 Le ez 80ceddce Fig 19 FUEL FILTER WATER SEPARATOR 1 FUEL FILTER WATER SEPARATOR ASSEMBLY 2 WATER IN FUEL SENSOR 3 FUEL HEATER OPERATION The element inside the heater assembly is made of a Positive Temperature Coefficient PTC material and has power applied to it by the fuel heater relay anytime the ignition key is in the on position PTC material has a high resistance to current flow when its temperature is high which mea
135. TITTJ146010001 05 05 31 AURAIT P52 119099 RFE LABEL 80af3150 Fig 1 Transmission Part And Serial Number Location 1 IDENTIFICATION NUMBERS STAMPED GEAR RATIOS The 545RFE gear ratios are 15 EE 3 00 1 bad 1 67 1 2nd Prime eu 1 50 1 ede anaes eh 1 00 1 0 75 1 DEDI tered ana se 0 67 1 Reverse 3 00 1 OPERATION The 545RFE offers full electronic control of all automatic up and downshifts and features real time adaptive closed loop shift and pressure control Elec tronic shift and torque converter clutch controls help protect the transmission from damage due to high temperatures which can occur under severe operat ing conditions By altering shift schedules line pres sure and converter clutch control these controls reduce heat generation and increase transmission cooling To help reduce efficiency robbing parasitic losses the transmission includes a dual stage transmission fluid pump with electronic output pressure control Under most driving conditions pump output pres sure greatly exceeds that which is needed to keep the clutches applied The 545RFE pump pressure control system monitors input torque and adjusts the pump pressure accordingly The p
136. TON RING EITIING ied ee pee ees 824 37 REMOVAL ais aee RES ai See 37 INSPECTION 39 INSTALLATION 40 VIBRATION DAMPER REMOVAL vec cece ee RR RS eae ees 41 INSTALLATION 42 INTERNAL VACUUM PUMP DESCRIPTION 42 REMOVAL eee deeds 42 INSTALLATION 42 ENGINE COVER FRONT DESCRIPTION 43 REMOVAL pid ee REF ER eee ale ene 43 INSTALLATION 44 OIL DESCRIPTION 44 OIL FILTER ADAPTER DESGRIPTION x ERA cae ens 45 OIL PAN REMOVAL cases eeu EURO EE EE UE YE 45 INSTALLATION 45 9 2 ENGINE OIL PRESSURE RELIEF VALVE DESCRIPTION REMOVAL s bie accu RE S INSTALLATION OIL PRESSURE SENSOR SWITCH DESCRIPTION OPERATION OIL PUMP REMOVAL REMOVAL OIL PUMP PICKUP TUBE REMOVAL OIL PUMP INSTALLATION INSTALLATION OIL PUMP PICKUP TUBE INSTALLATION OIL PUMP OIL JET DESCRIPTION REMOVAL oe INSTALLATION INTAKE MANIFOLD DESCRIPTION REMOVAL ada ee tiene INSTALLATION eR tg EXHAUST MANIFOLD REMOVAL INSTALLATION VALVE TIMING STANDARD PROCEDURE LOCKING ENGINE 90 DEGREES AFTER TDC 46 47 47 47 47 48 BALANCE SHAFT DESCRIPTION OPERATION REMOV
137. TREME PRESSURE FROM THE INJECTION PUMP TO THE FUEL INJECTORS THIS MAY BE AS HIGH AS 1600BAR 23 200 PSI USE EXTREME CAUTION WHEN INSPECTING FOR HIGH PRESSURE FUEL LEAKS FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE SKIN CAUSING PERSONAL INJURY OR DEATH INSPECT FOR HIGH PRESSURE FUEL LEAKS WITH A SHEET OF CARDBOARD WEAR SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTH ING WHEN SERVICING FUEL SYSTEM 1 Install fuel pressure sensor in fuel rail Fig 13 2 Connect fuel pressure sensor electrical connec tor Fig 13 3 Install engine cover Refer to 9 ENGINE COVER INSTALLATION 4 Connect negative battery cable KJ AUTOMATIC TRANSMISSION 545RFE TABLE OF CONTENTS page AUTOMATIC TRANSMISSION 545RFE AUTOMATIC TRANSMISSION 545RFE TABLE OF CONTENTS page AUTOMATIC TRANSMISSION 545RFE DESCRIPTION Pe a 1 OPERATION munai 484 484 2 DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING AUTOMATIC TRANSMISSION 3 DIAGNOSIS AND TESTING ROAD TESTING d eR daw eae 3 DIAGNOSIS AND TESTING HYDRAULIC PRESSURE TEST eR RR AR 4 SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS 6 SPECIFICATIONS TRANSMISSION 27 HOLDING CLUTCHES DESCRIPTION RR iddes 28 OPERATION 30 INPUT CLUTCH ASSEMBLY DESCRIPTION 30 AUTOMATIC TRAN
138. UBE 10 OIL PICK UP TUBE RETAINING BOLT INSTALLATION 1 Before installation of the balance shaft assem bly the 1 cylinder must be brought to TDC Using special tool VM 8872 roll engine over by hand until tool can be inserted into engine to transmission adpater plate locking flywheel from turning Once the 1 cylinder is brought to TDC the balance shaft assembly can be installed Fig 70 9 52 ENGINE BALANCE SHAFT Continued 8106b1e1 Fig 70 TDC ALIGNMENT ENGINE BLOCK STARTER STRUCTURAL SUPPORT TDC ALIGNMENT PIN ENGINE OIL PICK UP TUBE BALANCE SHAFT ASSEMBLY 2 With balance shaft assembly on work bench Insert special tool VM 1056 into balance shaft assem bly Fig 71 This will ensure proper balance shaft and crankshaft timing after assembly 3 Install balance shaft assembly and retaining bolts Torque bolts to 32 4N m 4 Install oil pump pickup tube Refer to 9 ENGINE LUBRICATION OIL PUMP INSTALLA TION 5 Install oil pan Refer to 9 ENGINE LUBRI CATION OIL PAN INSTALLATION 6 Refill engine oil to proper level 7 Connect negative battery cable KJ 80c7595e Fig 71 BALANCE SHAFT ALIGNMENT PIN VM 1056 1 VM 1056 2 BALANCE SHAFT ASSEMBLY TIMING BELT CHAIN COVER S REMOVAL REMOVAL TIMING BELT INNER COVER 1 Disconnect negative battery cable 2 Remove engine cover Refer to 9 ENGINE COVER REMOVAL 3
139. VER INSTALLATION 6 Install crankshaft hub and retaining bolt Torque bolt to 304N m 7 Install timing belt inner cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 8 Install timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION 9 Install timing belt outer cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 10 Install vibration damper crankshaft pulley Refer to 9 BLOCK VIBRATION DAMPER INSTALLATION 80c6ca57 Fig 36 VM 1061 PLACEMENT VM 1061 FRONT ENGINE COVER PRESS BENCH SLEEVE FROM VM 1061 11 Install cooling fan support Refer to 7 COOL ING ENGINE RADIATOR FAN REMOVAL 12 Install accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 13 Install cooling fan and fan drive viscous clutch assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH INSTALLATION 14 Connect negative battery cable KJ CRANKSHAFT OIL SEAL REAR REMOVAL This must be done with either the engine or trans mission removed from vehicle 1 Remove flywheel assembly 2 Pry out old crankshaft oil seal INSTALLATION NOTE To prevent potential oil leaks DO NOT touch the rear crankshaft inner seal Always handle the seal from the outer diameter 1 Using special tool VM 1050 install rear crank
140. With Auxiliary Heater Engine Oil Capacity 6 0L W Filter Change Timing System Belt Driven DOHC Overhead Camshafts Air Intake Dry Filter With Turbocharger and Charge Air Cooler Fuel Supply Vane Pump Incorporated In Injection Pump Fuel System Direct Fuel Injection Common Rail System Combustion Cycle 4 Stroke ENGINE 9 3 DESCRIPTION SPECIFICATION di Difference Between Cylinders Cooling System Water Cooling Injection Pump Rotary Pump and Electronically Managed Lubrication Pressure Lubricated By Rotary Pump Minimum Oil Pressure 0 7 Bar at Idle Warm 2 Bar at 3800 rom Engine Rotation Clockwise Viewed From Front Cover 80cb4237 Fig 1 2 5L 2 8L COMMON RAIL DIESEL ENGINE DESCRIPTION ENGINE COVER The engine cover is made of plastic and used cos metically to cover the top of the engine Fig 2 REMOVAL REMOVAL 1 Disconnect negative battery cable 2 Disconnect under hood lamp from the hood assembly 3 With assistance from another person remove the hood assembly from the vehicle 4 Drain cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 5 Remove engine cover Refer to 9 ENGINE REMOVAL 9 4 ENGINE KJ ENGINE 2 5L 2 8L TURBO DIESEL Continued 6 Remove air filter assembly from the engine bay 7 Recover refrigerant from A C system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE 8 Disconnect high s
141. Xu VENTED TORQUE CONVERTER TORQUE CONVERTER CLUTCH RELEASED CLUTCH APPLIED 80bfe276 Fig 22 Torque Converter Fluid Operation Typical 1 APPLY PRESSURE 3 RELEASE PRESSURE 2 THE PISTON MOVES SLIGHTLY FORWARD 4 THE PISTON MOVES SLIGHTLY REARWARD from rotating With the stator locked the oil strikes the stator blades and is redirected into a helping direction before it enters the impeller This circula tion of oil from impeller to turbine turbine to stator FLOW IS and stator to impeller can produce a maximum torque multiplication of about 2 4 1 As the turbine STRAIGHT begins to match the speed of the impeller the fluid ee that was hitting the stator in such as way as to LESS cause it to lock up is no longer doing so In this con dition of operation the stator begins to free wheel and the converter acts as a fluid coupling TORQUE CONVERTER CLUTCH TCC In a standard torque converter the impeller and turbine are rotating at about the same speed and the stator is freewheeling providing no torque multipli cation By applying the turbine s piston and friction material to the front cover a total converter engage ment can be obtained The result of this engagement is a direct 1 1 mechanical link between the engine and the transmission The clutch can be engaged in second third fourth and fifth gear ranges depending on overdrive control switch position If the overdrive control switch is in the normal ON positio
142. Y DRIVE SPECIFICATIONS ACCESSORY BELT TENSION ACCESSORY DRIVE BELT 2 5L 2 8L DIESEL ENGINE A C Compressor Dynamic Tensioner Generator BELT TENSIONERS DESCRIPTION This engine is equipped with a spring loaded auto matic belt tensioner Fig 1 This tensioner main tains constant belt tension at all times and requires no maintenance or adjustment CAUTION Do not attempt to check belt tension with a belt tension gauge on vehicles equipped with an automatic belt tensioner OPERATION Fig 1 ACCESSORY BELT ROUTING IDLER PULLEY GENERATOR IDLER PULLEY A C COMPRESSOR COOLING FAN SUPPORT VIBRATION DAMPER BELT TENSIONER POWER STEERING PUMP ACCESSORY DRIVE BELT 0 VISCOUS HEATER WARNING THE AUTOMATIC BELT TENSIONER ASSEMBLY IS SPRING LOADED DO NOT ATTEMPT TO DISASSEMBLE THE TENSIONER ASSEMBLY 7 10 ACCESSORY DRIVE KJ BELT TENSIONERS Continued The automatic belt tensioner maintains correct belt 2 Remove accessory drive belt Fig 2 Refer to 7 tension using a coiled spring within the tensioner COOLING ACCESSORY DRIVE DRIVE BELTS housing The spring applies pressure to the tensioner REMOVAL arm pressing the arm into the belt tensioning the belt 3 Remove belt tensioner retaining bolt and If new belt is being installed the arrow must be remove tensio
143. ached The gasket in the cap seals the filler neck so that vacuum can be maintained allowing coolant to be drawn back into the radiator from the reserve tank If the gasket is dirty or damaged a vacuum may not be achieved resulting is loss of coolant and eventual overheating due to low coolant level in radiator and engine DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING COOLING SYSTEM PRESSURE CAP Dip the pressure cap in water Clean any deposits off the vent valve or its seat and apply cap to end of the Pressure Cap Test Adaptor that is included with the Cooling System Tester 7700 Working the plunger bring the pressure to 104 kPa 15 psi on the gauge If the pressure cap fails to hold pressure of at least 97 kPa 14 psi replace the pressure cap CAUTION The Cooling System Tester Tool is very sensitive to small air leaks that will not cause cool ing system problems A pressure cap that does not have a history of coolant loss should not be replaced just because it leaks slowly when tested with this tool Add water to the tool Turn tool upside down and recheck pressure cap to confirm that cap is bad If the pressure tests properly while positioned on Cooling System Tester Fig 13 but will not hold pressure or vacuum when positioned on the filler neck Inspect the filler neck and cap top gasket for irregularities that may prevent the cap from sealing properly DIAGNOSIS AND TESTING PRESSURE RELIEF TEST The pr
144. aft and main bearings with clean engine oil 3 Install crankshaft supports on crankshaft Fig 32 Torque bolts to 44 1N m KJ gt 80adf230 Fig 32 CRANKSHAFT ASSEMBLY 1 CRANKSHAFT SUPPORT HALVE 2 MAIN BEARING HALVE 3 CRANKSHAFT 4 MAIN BEARING HALVE 5 CRANKSHAFT SUPPORT HALVE 6 MAIN BEARING SUPPORT BOLTS 7 WASHERS Kj T e f 9 33 CRANKSHAFT MAIN BEARINGS Continued FRONT CRANKSHAFT MAIN BEARING CRANKSHAFT OIL SEAL FRONT 1 Using special tool VM 1073 push front crank shaft main bearing in engine block Fig 33 REMOVAL 1 Disconnect negative battery cable 2 Remove cooling fan and fan drive viscous clutch assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 3 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 4 Remove cooling fan support Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL 5 Remove vibration damper crankshaft pulley Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER REMOVAL 6 Remove outer timing belt cover Refer to 9 ENGINENALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 7 Remove timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL 8 Remove timing belt inner cover Refer to 9 ax amp ao ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL Fig 33 FRONT MAIN BEARING INSTALLATION m 1 FRONT CRANKSHAFT MAIN BEAR
145. ank module are equipped with tension springs Fig 16 These springs hold module to bottom of the fuel tank in 2 formed guides Fig 17 Release module assembly from these 2 guides by sliding toward right side of fuel tank c Lift assembly fom fuel tank 80c8a65d Fig 16 LOWER SECTION FUEL PUMP MODULE 1 LOWER SECTION FUEL PUMP MODULE 2 RELEASE LOCK AND TAB 3 TENSION SPRINGS INSTALLATION CAUTION Whenever fuel tank module is serviced pump module gasket must be replaced 1 Position lower section of fuel pump module assembly into fuel tank 2 The bottom of fuel tank has 2 formed guides Lock module assembly into these 2 guides by sliding toward left side of fuel tank 3 Push down on plastic tab to lock module to fuel tank guides KJ 80c8a672 Fig 17 FUEL TANK MODULE GUIDES IN FUEL TANK 1 FUEL TANK INSIDE LOWER 2 FUEL TANK MODULE GUIDES 4 Connect fuel supply and return lines to bottom of upper tank module section 5 Connect electrical connector to bottom of upper tank module section 6 Position tank module into fuel tank Notch on module must be facing rear of tank 7 Position lock ring to module Tap lockring using a brass drift and hammer dockwise until rotated up to built on stops 8 Attach snap on 2 fuel filter fuel lines to top of fuel pump module 9 Fill fuel tank with fuel 10 Start engine and check for fuel leaks 11 Apply silicone
146. aring supports Fig 24 There is a difference between crankshafts on the 2 5L and the 2 8L The 2 5L has a smooth front surface where as the 2 8L has a groove The crankshafts ARE NOT inter changeable OPERATION The crankshaft transfers force generated by com bustion within the cylinder bores to the flywheel or flexplate KJ G 2 4 80adf230 Fig 24 5 ASSEMBLY TYPICAL CRANKSHAFT SUPPORT HALVE MAIN BEARING HALVE CRANKSHAFT MAIN BEARING HALVE CRANKSHAFT SUPPORT HALVE MAIN BEARING SUPPORT BOLTS WASHERS STANDARD PROCEDURE CHECKING CRANKSHAFT END PLAY 1 Mount a dial indicator to a stationary point at rear of engine Locate the probe perpendicular against the flywheel Fig 25 2 Move the crankshaft all the way to the front of its travel 3 Zero the dial indicator 4 Move the crankshaft all the way to the rear and read dial indicator For crankshaft end play dearances Refer to 9 ENGINE SPECIFICA TIONS REMOVAL 1 Remove engine from vehide Refer to 9 ENGINE REMOVAL 2 Mount engine on an engine stand CRANKSHAFT Continued Edi E ao bk U NE SS 80cb3a1b Fig 25 CHECKING CRANKSHAFT ENDPLAY FLYWHEEL RETAINING BOLTS DIAL INDICATOR FLYWHEEL TRANSMISSION ADAPTER PLATE BOLT TRANSMISSION ADAPTER PLATE REAR MAIN BEA
147. at each coolant passage 4 Inspect valves for burned cracked or warped heads 5 Inspect for scuffed or bent valve stems 6 Replace valves displaying any damage 7 Check valve spring height Fig 3 VALVE REFACING 1 Use a valve refacing machine to reface the intake and exhaust valves to the specified angle 2 After refacing a margin of at least 4 52 4 49 mm 178 177 inch must remain Fig 4 If the mar gin is less than 4 49 mm 177 inch the valve must be replaced ENGINE 9 15 z H2 p 1 H3 80bfeles Fig 3 VALVE SPRING CHART LOAD Kg HEIGHT mm STATE P1 0 00 H1 45 26 FREE LENGTH P2 rr H2 38 00 VALVE CLOSED 10 P3 395 5 28 20 VALVE OPEN VALVE SEAT REFACING 1 Install a pilot of the correct size in the valve guide bore Reface the valve seat to the specified angle with a good dressing stone Remove only enough metal to provide a smooth finish 2 Use tapered stones to obtain the specified seat width when required VALVE STAND DOWN Valve stand down is to maintain the adequate com pression ratio 1 Invert cylinder head 2 Fit each valve to its respective valve guide 3 Using a straight edge and feeler gauge check valve head stand down Inlet valve head stand down 1 08 to 1 34 mm 042 to 052 ins and exhaust valve stand down 99 to 1 25 mm 035 to 049 ins 4 If valve head stand down is not in accordance with above discard original valves check stand
148. ator cap 3 With heater control unit in the HEAT position operate engine with radiator cap in place 4 After engine has reached normal operating temperature shut engine off and allow it to When engine is cooling down coolant will be drawn into the radiator from the reserve overflow tank 5 Add coolant to reserve overflow tank as neces sary Only add coolant to the reserve overflow tank when the engine is cold Coolant level in a warm engine will be higher due to thermal expansion COOLANT RECOVERY PRESS CONTAINER DESCRIPTION This system works along with the radiator pres sure cap This is done by using thermal expansion and contraction of the coolant to keep the coolant free of trapped air It provides e A volume for coolant expansion and contraction e A convenient and safe method for checking ad justing coolant level at atmospheric pressure This is done without removing the radiator pressure cap e Some reserve coolant to the radiator to cover minor leaks and evaporation or boiling losses ENGINE 7 17 As the engine cools a vacuum is formed in the cooling system of both the radiator and engine ant will then be drawn from the coolant tank and returned to a proper level in the radiator The coolant reservoir overflow system has a radia tor mounted pressurized cap an overflow tube and a plastic coolant reservoir overflow tank mounted to the right side of the cowl It is mounted to the cowl wi
149. aud 1d H31H3ANOO 00 HOLVINNNDOV 0V za HOLf119 19 3suaAau ou 55 cuc 2 asua dd MOT u1 ao 99W3 uvao GNOOAS 21 14 AUTOMATIC TRANSMISSION 545RFE AUTOMATIC TRANSMISSION 545RFE Continued 21 15 AUTOMATIC TRANSMISSION 545RFE AUTOMATIC TRANSMISSION 545RFE Continued pa eoeog GNOO3S DITINVYCAH 0091 IV NO 55 11095 3NH E an SW ISd s3unissadud 08 01 811 568 391 55 gaziouaNa SdION3 TOS ERRA fo f LE PE aH Sd La ae wr ee TT a A 064696 Li H 14 IN3A A Q3IVA3 T4373 HOSN3S S3ud ANIT Sd1 7106 1OHLNOO S3Hd SOd 10374S ILINW SW HOLIMS S3Hd Sd 1558 14 10 H31H3ANO2 90 1 HOLfT1O aSuaAau ou an 99 Alou 6 2 0 1 HO1f119 puz oz MO T H1 22 uv3o AWIdd GNOOAS Y AUTOMATIC TRANSMISSION 545RFE AUTOMATIC TRANSMISSION 545RFE Continued 21 16 86290808 IOWA HV39 GNODAS
150. battery requires twice the charging time of a small capacity battery e Temperature A longer time will be needed to charge a battery at 18 C 0 F than at 27 C 80 F When a fast battery charger is connected to a cold battery the current accepted by the battery will be very low at first As the battery warms it will accept a higher charging current rate amperage e Charger Capacity A battery charger that supplies only five amperes will require a longer charging time A battery charger that supplies eight amperes will require a shorter charging time e State Of Charge A completely discharged bat tery requires more charging time than a partially discharged battery Electrolyte is nearly pure water in a completely discharged battery At first the charging current amperage will be low As the bat tery charges the specific gravity of the electrolyte will gradually rise The Battery Charging Time Table gives an indica tion of the time required to charge a typical battery at room temperature based upon the battery state of charge and the charger capacity SPIRAL PLATE BATTERY CHARGING TIME TABLE Hours Charging 21 70 F Chargin Voltage 12 25 to 12 49 12 00 to 12 24 10 00 to 11 99 Below 10 00 3 hours 5 hours 7 hours 9 hours 8F 4 ENGINE SYSTEMS BATTERY Continued STANDARD PROCEDURE USING MICRO 420 BATTERY TESTER 80c9
151. be 0 00 0 05 mm 10 Reassemble engine 11 Install engine in vehicle PISTON amp CONNECTING ROD DESCRIPTION The pistons are of a free floating design Oil jets in the engine block lubricate cool the piston and assembly The connecting rods have a pressed in place wrist pin bushing which is lubricated by the oil jets Fig 43 STANDARD PROCEDURE PISTON RING FITTING 1 Wipe cylinder bore clean Insert ring and push down with piston to ensure it is square in bore The ring gap measurement must be made with the ring positioning at least 12 mm 0 50 in from bottom of cylinder bore Fig 44 Check gap with feeler gauge Top compression ring gap 30 to 45mm 0118 to 0177 in Second compression ring gap 30 to 45mm ENGINE 9 37 80c6c8fe Fig 43 PISTON AND CONNECTING ROD ASSEMBLY PISTON PIN PISTON SNAP RING PAINTED CONNECTING ROD ALIGNMENT NUMBERS CONNECTING ROD BOLT CONNECTING ROD BEARING CONNECTING ROD SNAP RING 0118 0177 in Oil control ring gap 25 to 50mm 0098 to 0196 in 2 If ring gaps exceed dimension given new rings or cylinder liners must be fitted Keep piston rings in piston sets 3 Check piston ring to groove clearance Fig 45 Top compression ring gap 080 to 130mm 0031 to 0051 in Second compression ring gap 070 to 110mm 0027 to 0043 in Oil control ring gap 040 to 080mm 0015 to 0031 in
152. belt inner cover to engine front cover seal 2 Install timing belt inner cover to cylinder head cover gaskets 3 Install timing belt inner cover and retaining bolts Torque 10mm bolts to 47 1N m and 8mm bolts to 10 8N m 4 Install injection pump sprocket Refer to 14 FUEL SYSTEM FUEL DELIVERY FUEL INJEC TION PUMP INSTALLATION 5 Install camshaft sprockets Torque bolts to 108N m 6 Install timing belt idler pulleys Refer to 9 ENGINE VALVE TIMING TIMING BELT IDLER PULLEY INSTALLATION 7 Install timing belt and tensioner Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION 8 Install timing belt outer cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN 5 INSTALLATION 9 Install vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER INSTAL LATION 10 Install cooling fan support Refer to 7 COOLING ENGINE RADIATOR FAN INSTALLA TION 11 Install accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 12 Install cooling fan and fan drive viscous dutch assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH INSTALLATION 13 Install engine cover Refer to 9 ENGINE COVER INSTALLATION 14 Connect negative battery cable INSTALLATION TIMING BELT OUTER COVER 1 Install timing belt outer cover seal and cover Torque 3mm bolts to 10 8 and 8mm bolts to 10 8N m 2
153. both heater hoses should be hot to the touch If only one of the hoses is hot the water pump may not be operating correctly The accessory drive belt may also be slipping causing poor water pump operation 1 The lower gauge reading may be normal 2 Pressure test cooling system Repair leaks as necessary 3 Remove heater hoses and check for obstructions Repair as necessary 4 Locate kinked area Repair as necessary 5 Refer to water pumps in this group Repair as necessary If a slipping belt is detected refer to Engine Accessory Drive Belts in this group Repair as necessary COOLING 2 5L 2 8L TURBO DIESEL COOLING 2 5L 2 8L TURBO DIESEL Continued CONDITION POSSIBLE CAUSES 7 7 CORRECTION HEAT ODOR STEAM IS COMING FROM FRONT OF VEHICLE NEAR GRILL AREA WHEN WEATHER 15 WET ENGINE IS WARMED UP AND RUNNING AND VEHICLE IS STATIONARY TEMPERATURE GAUGE IS IN NORMAL RANGE 1 Various heat shields are used at certain drive line components One or more of these shields may be missing 2 Is temperature gauge reading above the normal range 3 Is the Cooling fan operating correctly 4 Has undercoating been applied to any unnecessary components 1 During wet weather moisture snow ice or rain condensation on the radiator will evaporate when the thermostat opens This opening allows heated water into the radiator When the moisture contacts the hot radiator steam may be em
154. ce exerted on the control plunger the nozzle needle opens as a result and injection starts Fig 11 Injector opens fully The control plunger reaches its upper stop where it remains supported by a cushion of fuel which is gen erated by the flow of fuel between the bleed and feed orifices The injector nozzle has now opened fully and the fuel is injected into the combustion chamber at a pressure almost equal to that in the fuel rail Fig 11 Injector closes end of injection As soon as the solenoid valve is no longer trig gered the valve spring forces the armature down wards and the ball doses the bleed orifice The armature is a 2 piece design Here although the armature plate is guided by a driver shoulder in its downward movement it can overspring with the return spring so that it exerts no downwards acting forces on the armature and the ball The dosing of the bleed orifice lead to pressure build up in the con trol chamber via the input from the feed orifice This pressure is the same as that in the rail and exerts an increased force on the control plunger through its end face This force together with that of the spring now exceeds the force exerted by the chamber volume FUEL INJECTION 14 23 and the nozzle needle closes Injection ceases as soon as the nozzle needle comes up against its bottom stop again Fig 11 REMOVAL WARNING HIGH PRESSURE FUEL LINE DELIVER DIESEL FUEL UNDER EXTREME PRESSURE FROM T
155. ct negative battery cable 2 Remove engine cover Refer to 9 ENGINE COVER REMOVAL 3 Remove cooling fan and fan drive viscous dutch assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 4 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 5 Remove cooling fan support Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL 6 Bring piston 1 to TDC turn crankshaft until notch on the crankshaft hub is at the 12 o dock posi tion 7 Looking at the engine from the belt side rotate the crankshaft 90 clockwise 8 Install the 90 alignment pin into the crank case threaded hole on the right side of the engine to lock the crankcase make sure the crankshaft does not rotate 9 Remove vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER REMOVAL 10 Paint mark the crankshaft hub and the oil pump cover this will be useful during the timing check 11 Remove the alternator 12 Remove the intake and exhaust camshaft plugs from the camshaft cover to introduce the cam shaft timing pins if the engine is timed correctly the pins can be installed 9 56 ENGINE KJ TIMING BELT CHAIN AND SPROCKET S Continued 13 Remove timing belt outer cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 14 Loosen timing belt tensioner and remove tim ing belt Fig 76 80ae1cd6 Fig 76 TIMING BELT AN
156. d Battery System Inspection for the proper battery inspection procedures Refer to Stan dard Procedures for the proper battery charging pro cedures MICRO 420 BATTERY TESTER The Micro 420 automotive battery tester is designed to help the dealership technicians diagnose the cause of a defective battery Follow the instruc tion manual supplied with the tester to properly diagnose a vehicle If the instruction manual is not available refer to the standard procedure in this sec tion which includes the directions for using the Micro 420 battery tester WARNING IF THE BATTERY SHOWS SIGNS OF FREEZING LEAKING OR LOOSE POSTS DO NOT TEST ASSIST BOOST OR CHARGE THE BATTERY MAY ARC INTERNALLY AND EXPLODE PERSONAL INJURY AND OR VEHICLE DAMAGE MAY RESULT WARNING EXPLOSIVE HYDROGEN GAS FORMS IN AND AROUND THE BATTERY DO NOT SMOKE USE FLAME OR CREATE SPARKS NEAR THE BAT TERY PERSONAL INJURY AND OR VEHICLE DAM AGE MAY RESULT WARNING THE BATTERY CONTAINS SULFURIC ACID WHICH IS POISONOUS AND CAUSTIC AVOID CONTACT WITH THE SKIN EYES OR CLOTHING IN THE EVENT OF CONTACT FLUSH WITH WATER AND CALL A PHYSICIAN IMMEDIATELY KEEP OUT OF THE REACH OF CHILDREN A battery that will not accept a charge is faulty and must be replaced Further testing is not required A fully charged battery must be tested to determine its cranking capacity A battery that is ful ly charged but does not pass the Micro 420 or load test is faulty and m
157. down with new valves and recut valve seat inserts to obtain correct stand down 9 16 ENGINE CYLINDER HEAD Continued INTAKE EXHAUST A A 55 30 45 20 55 40 amp 45 35 INTAKE EXHAUST B N 7 HN 5 H 45 Ns H H gt 54 20 442 20 54240 449 40 80a2d942 Fig 4 VALVE SPECS MEASUREMENT INTAKE EXHAUST A 7 940 7 960 7 922 7 940 B 8 00 8 015 8 000 8 015 C 1 08 1 34 0 990 1 250 40 07 2 2 0 08 2 09 0 09 1 80 2 20 1 65 2 05 2 73 3 44 2 45 3 02 35 964 35 987 36 050 36 066 7 00 7 05 3 10 3 25 41 962 41 985 42 070 42 086 7 14 7 19 3 11 3 26 KJ VALVE GUIDES 1 Valve Guides height requirement 2 Measurement A Fig 5 16 50 17 00 mm Measurment 14 50 15 00 mm 80 02644 Fig 5 VALVE GUIDE HEIGHT VALVE STEM TO GUIDE CLEARANCE MEASUREMENT 1 Measure and record internal diameter of valve guides Valve guide internal diameter is 8 0 to 8 015 mm 3149 to 3155 ins 2 Measure valve stems and record diameters Intake valve stem diameter 7 94 to 7 96 mm 3125 to 3133 in Exhaust valve stem diameter 7 92 to 7 94 mm 3118 to 31215 in 3 Subtract diameter of valve stem from internal diameter of its respective valve guide to obtain valve stem clearance in valve guide Clearance of inlet valve stem i
158. e Intake 5 4 Air Temperature Sensor Bolts High Pressure Injection 24 4 18 Pump Nuts High Pressure Injection 88 3 65 Pump Sprocket Nut Fuel Injector Retaining 32 4 Bolts Fie Une Pa High Pressure Fuel Lines 14 4 FUEL DELIVERY FUEL DELIVERY TABLE OF CONTENTS page FUEL FILTER WATER SEPARATOR DESCRIPTION 22522 222 442 emm ee 4 OPERATION aces netus 4 REMOVAL 254252995 eee ee ARES RE E 4 INSTALLATION 5 WATER IN FUEL SENSOR DESCRIPTION he RR Pe AR 6 OPERATION nere be RARE E ge 6 REMOVAL 5 55 65 Ue ERG 6 INSTALLATION 6 FUEL RAIL DESCRIPTION case 4 ba ae 6 OPERATION i22 4 cem 6 REMOVAL epe 7 INSTALLATION 8 FUEL LINES DESCRIPTION DESCRIPTION 8 DESCRIPTION HIGH PRESSURE FUEL LINES zo ix grew Gee La ee we E ts 9 OPERATION HIGH PRESSURE FUEL LINES 9 DIAGNOSIS AND TESTING HIGH PRESSURE FUEL LINES FUEL FILTER WATER SEPARATOR DESCRIPTION The fuel filter water separator assembly is located in the left rear corner of the engine compartment Fig 1 OPERATION The fuel filter water separator protects the fuel injection pump by removing water and contaminants from the fuel The construction of the filter separator allows fuel to pass through it but helps prevent
159. e 3 4 or 4 5 shifts The FOURTH and FIFTH gear upshifts occurs automatically when the overdrive selector switch is in the ON position An upshift to FOURTH and FIFTH gears may not occur or may be delayed in some of the possible shift schedules Refer to 8 ELECTRICAL ELECTRONIC CONTROL MOD ULES TRANSMISSION CONTROL MODULE OPERATION KJ SOLENOID SWITCH VALVE DESCRIPTION The Solenoid Switch Valve SSV is located in the valve body and controls the direction of the transmis sion fluid when the L R TCC solenoid is energized OPERATION The Solenoid Switch Valve controls line pressure from the LR TCC solenoid In 1st gear the SSV will be in the downshifted position thus directing fluid to the L R dutch circuit In 2nd 3rd 4th and 5th gears the solenoid switch valve will be in the upshifted position and directs the fluid into the torque converter clutch TCC circuit When shifting into 1st gear a special hydraulic sequence is performed to ensure SSV movement into the downshifted position The L R pressure switch is monitored to confirm SSV movement If the move ment is not confirmed the L R pressure switch does not dose 2nd gear is substituted for 1st A DTC will be set after three unsuccessful attempts are made to get into 1st gear in one given key start TORQUE CONVERTER OPERATION The converter impeller Fig 22 driving member which is integral to the converter housing and bolted to the engine drive plate ro
160. e belts depends on belt condition and proper belt tension 80cdd35c Fig 4 ACCESSORY BELT ROUTING 1 IDLER PULLEY 2 GENERATOR 3 IDLER PULLEY 4 COMPRESSOR 5 COOLING FAN SUPPORT 6 VIBRATION DAMPER 7 BELT TENSIONER 8 POWER STEERING PUMP 9 ACCESSORY DRIVE BELT 10 VISCOUS HEATER OPERATION ACCESSORY DRIVE BELT The accessory drive belts form the link between the engine crankshaft and the engine driven accesso ries ACCESSORY DRIVE 7 11 DIAGNOSIS AND TESTING ACCESSORY DRIVE BELT VISUAL DIAGNOSIS When diagnosing serpentine accessory drive belts small cracks that run across the ribbed surface of the belt from rib to rib Fig 5 are considered normal These are not a reason to replace the belt However cracks running along a rib not across are not nor mal Any belt with cracks running along a rib must be replaced Fig 5 Also replace the belt if it has excessive wear frayed cords or severe glazing Refer to ACCESSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis 19007 44 Fig 5 BELT WEAR PATTERN 1 NORMAL CRACKS BELT OK 2 NOT NORMAL CRACKS REPLACE BELT NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle Before replacing a belt to resolve a noise condition inspect all of the accessory drive pulleys for alignment glazing or excessive end play 7 12 ACCESSORY DRIVE DRIVE BELT Continued ACCESSO
161. e clutch is applied the overdrive hub drives the reverse carrier input annulus assembly REVERSE CLUTCH The reverse dutch is hydraulically applied in reverse gear by pressurized fluid against the over drive reverse piston When the reverse dutch is applied the reaction annulus gear is driven INPUT CLUTCH ASSEMBLY Continued AUTOMATIC TRANSMISSION 545RFE 21 31 INPUT CLUTCH HUB O RING SEALS SEAL SNAP RING SNAP RING UD BALANCE PISTON SNAP RING UD PISTON SPRING 0 DISC 808a2e66 Fig 8 Input Clutch Assembly Part 1 11 12 13 14 15 16 17 18 19 20 UD CLUTCH PLATE CLUTCH RETAINER SEAL OD REV PISTON BELLEVILLE SPRING SNAP RING SEAL RINGS INPUT SHAFT LUBRICATION CHECK VALVE AND SNAP RING 21 32 AUTOMATIC TRANSMISSION 55 INPUT CLUTCH ASSEMBLY Continued S 29 808a2e68 Fig 9 Input Clutch Assembly Part 2 1 BEARING NUMBER 10 SNAP RING SELECT 2 OD HUB SHAFT 11 PLATE 3 SNAP RING WAVE 12 DISC 4 REV OD REACTION PLATE 13 OD CLUTCH 5 BEARING NUMBER 4 14 SNAP RING TAPERED 6 SNAP RING FLAT 15 UD OD REACTION PLATE 7 REVERSE HUB SHAFT 16 SNAP RING FLAT 8 REVERSE CLUTCH 17 UD HUB SHAFT 9 REVERSE REACTION PLATE 18 BEARING NUMBER 2 INPUT CLUTCH ASSEMBLY Continued DISASSEMBLY 1 Remove the reverse reaction plate selecti
162. e sealant applied to the threads 804368 5 Fig 4 CYLINDER HEAD ASSEMBLY 1 CYLINDER HEAD BOLT 2 GLOW PLUG 3 COOLANT TEMPERATURE SENSOR 4 CYLINDER HEAD ALIGNMENT DOWEL 5 GLOW PLUG HARNESS 6 CYLINDER LINER 7 CYLINDER BLOCK 8 CYLINDER HEAD GASKET 9 1 CYLINDER HEAD 0 ROCKER ARM ASSEMBLIES OPERATION The coolant temperature ECT sensor is a nega tive temperature coefficient NTC thermistor resis tance varies inversley with temperature This means at cold tempertures its resistance is high so the volt age signal will be high As coolant temperture increases resistance decreases and the signal voltage will be low This allows the sensor to provide an ana log voltage signal to the ECM 7 20 ENGINE ENGINE COOLANT TEMP SENSOR Continued REMOVAL WARNING DO NOT REMOVE OR LOOSEN THE COOLANT PRESSURE VENT CAP CYLINDER BLOCK DRAIN PLUGS OR THE DRAINCOCK WHEN THE SYSTEM IS HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM THE COOLANT CAN OCCUR 1 Disconnect negative battery cable 2 Drain the cooling system Refer to 7 COOL ING ENGINE COOLANT STANDARD PROCE DURE 3 Disconnect coolant temperature sensor electri cal connector Fig 5 4 Remove coolant temperature sensor from cylin der head Fig 5 804368 5 Fig 5 CYLINDER HEAD ASSEMBLY CYLINDER HEAD BOLT GLOW PLUG COOLANT TEMPERATURE SENSOR CYLINDER HEAD ALIGNMENT DOWE
163. eaks Repair as necessary COOLING 2 5L 2 8L TURBO DIESEL COOLING 2 5L 2 8L TURBO DIESEL Continued CONDITION POSSIBLE CAUSES 7 5 CORRECTION TEMPERATURE GAUGE READING IS INCONSISTENT FLUCTUATES CYCLES OR IS ERRATIC 1 During cold weather operation with the heater blower in the high position the gauge reading may drop slightly Fluctuation is also influenced by loads outside temperature and extended idle time with diesel engines 2 Temperature gauge or engine mounted gauge sensor defective or shorted Also corroded or loose wiring in this circuit 3 Gauge reading rises when vehicle is brought to a stop after heavy use engine still running 4 Gauge reading high after starting a warm up hot engine 5 Coolant level low in the coolant tank air will build up in the cooling system causing the thermostat to open late 6 Cylinder head gasket leaking allowing exhaust gases to enter the cooling system causing the thermostat to open late 7 Water pump impeller loose on shaft 8 Loose accessory drive belt water pump slipping 9 Air leak on the suction side of the water pump allowing air to build up in the cooling system causing the thermostat to open late 1 A normal condition No correction is necessary 2 Check operation of gauge and repair as necessary 3 A normal condition No correction needed Gauge should return to normal range after vehicle is driven
164. ean The coolant level in the recovery pressure container should be full Attach the Cooling System Tester 7700 or equiva lent to the radiator as shown in Fig 1 and apply 104 kPa 15 psi pressure If the pressure drops more than 13 8 kPa 2 psi in 2 minutes inspect all points for external leaks All radiator and heater hoses should be shaken while at 104 kPa 15 psi since some leaks occur only while driving due to engine movement 2 1 n 215 Vn Sah A 80ce7a49 Fig 1 PRESSURE TESTING COOLING SYSTEM 1 COOLANT PRESSURE TESTER 2 COOLANT RECOVERY PRESSURE CONTAINER If there are no external leaks after the gauge dial shows a drop in pressure detach the tester Start engine and run until the thermostat opens allowing the coolant to expand Reattach the cooling system tester If the needle on the dial fluctuates it indicates a combustion leak usually a head gasket leak WARNING WITH TOOL IN PLACE PRESSURE WILL BUILD UP RAPIDLY EXCESSIVE PRESSURE BUILT UP BY CONTINUOUS ENGINE OPERATION MUST BE RELEASED TO A SAFE PRESSURE POINT NEVER PERMIT PRESSURE TO EXCEED 138 kPa 20 psi If the needle on the dial does not fluctuate raise the engine rpm a few times If an abnormal amount of coolant or steam emits from the tailpipe it may indicate a coolant leak caused by a faulty head gas ket cracked engine block or cracked cylinder head There may be inter
165. ertain point Until additional engine cooling is necessary the fan will remain at a reduced rpm regardless of engine speed Nor mally less than three hundred 300 rpm Only when sufficient heat is present will the vis cous fan drive engage This is when the air flowing through the radiator core causes a reaction to the bimetallic coil t then increases fan speed to provide the necessary additional engine cooling Once the engine has cooled the radiator discharge temperature will drop The bimetallic coil again reacts and the fan speed is reduced to the previous disengaged speed DIAGNOSIS AND TESTING FAN DRIVE VISCOUS CLUTCH If the fan assembly free wheels without drag the fan blades will revolve more than five turns when spun by hand replace the fan drive This spin test must be performed when the engine is cool For the following test the cooling system must be in good condition It also will ensure against exces sively high coolant temperature WARNING BE SURE THAT THERE IS ADEQUATE FAN BLADE CLEARANCE BEFORE DRILLING KJ 1 Drill a 3 18 mm 1 8 in diameter hole in the top center of the fan shroud 2 Obtain a dial thermometer with an 8 inch stem or equivalent It should have a range of 18 to 105 C 0 to 220 F Insert thermometer through the hole in the shroud Be sure that there is adequate clearance from the fan blades 3 Connect a tachometer and an engine ignition timing light timing light
166. ery cable 2 Remove engine cover Refer to 9 ENGINE COVER REMOVAL 3 Remove cooling fan and fan drive viscous dutch assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL AGS y Y A 7 AYA Or WA 101 80 14149 Fig 73 TIMING BELT COVER INNER BANJO FITTING BRASS WASHERS FUEL INLET LINE FUEL OUTLET LINE BANJO FITTING INJECTION PUMP RETAINING NUT INJECTION PUMP MOUNTING STUDS INNER TIMING COVER SEAL 10 INNER TIMING COVER 11 RETAINING BOLT 12 RETAINING BOLT 13 RETAINING BOLT 14 HOSE CLAMP 15 CYLINDER HEAD COVER INTAKE MANIFOLD 16 FUEL RETURN LINE TO INJECTION PUMP 17 HOSE CLAMP 18 FUEL RETURN JUNCTION BLOCK RETAINING BOLT 19 FUEL RETURN JUNCTION BLOCK 4 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 5 Remove cooling fan support Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL 6 Remove vibration damper Refer to 9 BLOCK VIBRATION DAMPER REMOVAL 9 54 ENGINE KJ TIMING BELT CHAIN COVER S Continued 7 Remove timing belt outer cover retaining bolts and remove cover Fig 74 8106b420 Fig 74 TIMING BELT OUTER COVER 1 TIMING BELT 2 TIMING BELT OUTER COVER 3 TIMING BELT OUTER COVER RETAINING BOLTS INSTALLATION INSTALLATION TIMING BELT INNER COVER 1 Install timing
167. ery to discharge electrical current OPERATION The battery is designed to store electrical energy in a chemical form When an electrical load is applied to the terminals of the battery an electrochemical reac tion occurs This reaction causes the battery to dis charge electrical current from its terminals As the battery discharges a gradual chemical change takes place within each cell The chemical changes within the battery are caused by the movement of excess or free electrons between the positive and negative plate groups This movement of electrons produces a flow of electrical current through the load device attached to the battery terminals The battery is vented to release excess hydrogen gas that is created when the battery is being charged or discharged However even with these vents hydrogen gas can collect in or around the battery If hydrogen gas is exposed to flame or sparks it may ignite If the battery is equipped with removable cell caps add distilled water whenever the electrolyte level is below the top of the plates If the battery cell caps cannot be removed the battery must be replaced if the electrolyte level becomes low 8F 2 ENGINE SYSTEMS BATTERY Continued DIAGNOSIS AND TESTING BATTERY The battery must be completely charged and the terminals should be properly cleaned and inspected before diagnostic procedures are performed Refer to Battery System Cleaning for the proper cleaning pro cedures an
168. es loose 2 Cooling fan blades striking a surrounding object 3 Air obstructions at radiator or A C condenser 1 Replace cooling fan assembly 2 Locate point of fan blade contact and repair as necessary 3 Remove obstructions or clean debris from radiator or A C condenser INADEQUATE AIR CONDITIONER PERFORMANCE COOLING SYSTEM SUSPECTED 1 Radiator and or A C condenser is restricted obstructed or dirty insects leaves etc 2 Engine is overheating heat may be transferred from radiator to A C condenser High Under hood temperatures due to engine overheating may also transfer heat to A C condenser 3 The cooling system is equipped with air seals at the radiator and or A C condenser If these seals are missing or damaged not enough air flow will be pulled through the radiator and A C condenser 1 Remove restriction or clean debris from radiator or A C condenser 2 Correct overheating condition 3 Check for missing or damaged air seals Repair as necessary INADEQUATE HEATER PERFORMANCE MAY BE ACCOMPANIED BY LOW GAUGE READING 1 Diesel engines due to their inherent efficiency are slower to warm up than gasoline powered engines and will operate at lower temperatures when the vehicle is unloaded 2 Coolant level low 3 Obstruction in heater hose fitting at engine 4 Heater hose kinked 5 Water pump is not pumping water to heater core When the engine is fully warmed up
169. essure cap upper gasket seal pressure relief can be checked by removing the overflow hose at the radiator filler neck nipple Fig 14 Attach the Radiator Pressure Tool to the filler neck nipple and pump air into the radiator Pressure cap upper gas ket should relieve at 69 124 kPa 10 18 psi and hold pressure at 55 kPa 8 psi minimum 26 ENGINE RADIATOR PRESSURE CAP Continued D 9407 29 Fig 13 Testing Cooling System Pressure Cap 1 PRESSURE CAP 2 PRESSURE TESTER 9207 12 6 Fig 14 Radiator Pressure Cap Filler Neck OVERFLOW NIPPLE MAIN SPRING GASKET RETAINER STAINLESS STEEL SWIVEL TOP RUBBER SEALS VENT VALVE PRESSURE BOTTLE FILLER NECK WARNING THE WARNING WORDS DO NOT OPEN HOT ON THE RADIATOR PRESSURE CAP IS A SAFETY PRECAUTION WHEN HOT PRESSURE BUILDS UP IN COOLING SYSTEM TO PREVENT SCALDING OR INJURY THE RADIATOR CAP SHOULD NOT BE REMOVED WHILE THE SYSTEM IS HOT OR UNDER PRESSURE There is no need to remove the radiator cap at any time except for the following purposes 1 Check and adjust coolant freeze point 2 Refill system with new coolant 3 Conducting service procedures 4 Checking for vacuum leaks KJ WARNING IF VEHICLE HAS BEEN RUN RECENTLY WAIT 15 MINUTES BEFORE REMOVING CAP THEN PLACE A SHOP TOWEL OVER THE CAP AND WITH OUT PUSHING DOWN ROTATE COUNTERCLOCK WISE TO THE FIRST STOP ALLOW FLUIDS TO ESCAPE
170. essurized fluid against the 4C clutch piston When the 4C clutch is applied the reaction annulus gear is held or grounded to the transmission case LOW REVERSE CLUTCH The Low Reverse clutch is hydraulically applied in park reverse neutral and first gear only at low speeds by pressurized fluid against the Low Reverse clutch piston When the Low Reverse clutch is applied the input annulus assembly is held or grounded to the transmission case INPUT CLUTCH ASSEMBLY DESCRIPTION Three hydraulically applied input clutches are used to drive planetary components The underdrive over drive and reverse clutches are considered input clutches and are contained within the input clutch assembly Fig 8 and Fig 9 The input dutch assembly also contains Input shaft e Input hub e Clutch retainer Underdrive piston Overdrive reverse piston Overdrive hub Underdrive hub KJ OPERATION The three input clutches are responsible for driving different components of the planetary geartrain UNDERDRIVE CLUTCH The underdrive clutch is hydraulically applied in first second second prime and third direct gears by pressurized fluid against the underdrive piston When the underdrive clutch is applied the under drive hub drives the input sun gear OVERDRIVE CLUTCH The overdrive dutch is hydraulically applied third direct fourth and fifth gears by pressurized fluid against the overdrive reverse piston When the overdriv
171. g mounting nut counterclockwise as viewed from front Fig 9 Fig 10 Threads on viscous fan drive are RIGHT HAND 3 Do not attempt to remove fan fan drive viscous clutch assembly from vehicle at this time 4 Do not unbolt fan blade assembly from fan drive viscous dutch at this time 5 Remove fan shroud to radiator bolts 6 Remove fan shroud and fan blade fan drive vis cous dutch assembly as a complete unit from vehicle FAN DRIVE VISCOUS CLUTCH Continued 80b6b293 Fig 9 FAN DRIVE VISCOUS CLUTCH TYPICAL 1 SPECIAL TOOL 6958 SPANNER WRENCH 2 FAN 80cda6e4 Fig 10 COOLING FAN AND VISCOUS CLUTCH 1 COOLING FAN AND FAN DRIVE VISCOUS CLUTCH ASSEMBLY 2 FAN SUPPORT ENGINE 7 23 7 After removing fan blade fan drive viscous clutch assembly do not place viscous clutch in hori zontal position If stored horizontally silicone fluid in the fan drive viscous dutch could drain into its bear ing assembly and contaminate lubricant 8 Remove four bolts securing fan blade assembly to fan drive viscous clutch INSTALLATION 1 Assemble fan blade to viscous fan drive Tighten mounting bolts to 27 N m 20 ft Ibs torque NOTE The viscous fan and fan shroud must be installed as an assembly 2 Gently lay fan and viscous drive into fan shroud 3 Install the fan shroud to radiator mounting bolt Torque bolts to 5 5N m 4 Thread the fan and viscous drive onto the fan sup
172. h A C off when temperature gauge is at end of normal range 2 TRAILER TOWING Consult Trailer Towing section of owners manual Do not exceed limits 3 RECENT SERVICE OR ACCIDENT REPAIR Determine if any recent service has been per formed on vehicle that may effect cooling system This may be Engine adjustments incorrect timing Slipping engine accessory drive belt Brakes possibly dragging Changed parts incorrect water pump Reconditioned radiator or cooling system refill ing possibly under filled or air trapped in system NOTE If investigation reveals none of the previous items as a cause for an engine overheating com plaint refer to following Cooling System Diagnosis charts These charts are to be used as a quick reference only COOLING SYSTEM DIAGNOSIS DIESEL ENGINE CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READS LOW unloaded 2 Is the temperature gauge connected to the temperature gauge coolant sensor on the engine 3 Is the temperature gauge operating OK 1 Diesel engines due to their inherent efficiency are slower to warm up than gasoline powered engines and will operate at lower temperatures when the vehicle is 1 The low gauge reading may be normal Refer to thermostats in the manual text for information See Thermostat Diagnosis Diesel Engine 2 Check the engine temperature sensor connector in the engine compartment 3 Check gauge operation Repai
173. ide refrigerant line from the upper radiator support bracket 9 Remove upper radiator support bracket retain ing bolts and remove the support bracket 10 Remove high side refrigerant line retaining nut and remove the line from the condenser assem bly Position the line out of the way 11 Remove cooling fan and fan drive viscous clutch assembly 12 Remove fan shroud retaining bolts and remove fan assembly and shroud together 13 Disconnect charge air cooler hoses from charge air cooler 14 Disconnect engine coolant hoses from engine assembly 15 Disconnect coolant reservoir hose from radia tor 16 Remove low side refrigerant line retaining nut and remove line from the condenser assembly Posi tion the line out of the way 17 Remove condenser assembly retaining bolts and remove condenser from the vehicle 18 Remove power steering cooler retaining bolts and unclip air deflectors from both sides of the radi ator cooling module assembly 19 Lift cooling module assembly out of the engine bay 20 Remove charge air cooler hose from the intake manifold 21 Remove high side refrigerant line from A C compressor and remove high side line from the engine bay 22 Remove coolant reservoir retaining nuts and dips retaining electrical harness position reservoir aside to allow access to remaining hoses 23 Disconnect remaining hoses from coolant res ervoir and remove reservoir from the engine bay 24
174. ig 17 22 Lift cylinder head cover intake manifold from cylinder head Fig 17 NOTE When removing rocker arm and lifter assem blies be sure to keep them in order as they were removed from the cylinder head Always keep lifters in an upright position when removed from cylinder head 23 Remove rocker arm and lifter assemblies from cylinder head 24 Remove cylinder head cover intake manifold gasket from cylinder head INSTALLATION 1 Clean and inspect sealing surfaces 2 Install new gasket on cylinder head CYLINDER HEAD COVER Continued 80c6d168 Fig 17 CYLINDER HEAD COVER INTAKE MANIFOLD ASSEMBLY CYLINDER HEAD COVER INTAKE MANIFOLD BOLTS LONG CYLINDER HEAD COVER INTAKE MANIFOLD CYLINDER HEAD CYLINDER HEAD COVER INTAKE MANIFOLD GASKET CYLINDER HEAD COVER INTAKE MANIFOLD BOLTS SHORT AUN 3 Install rocker arm and lifter assemblies in cyl inder head Be sure to put rocker arm and lifter assemblies in same location as removed 4 Install cylinder head cover intake manifold alignment studs in cylinder head Fig 18 5 Install cylinder head cover intake manifold over alignment stud NOTE Be sure to lubricate cylinder head cover in take manifold retaining bolts with engine oil before assembly If new bolts are being installed DO NOT lubricate before assembly 6 Install two cylinder head cover intake manifold retaining bolts and tighten finger tight 7 Remove a
175. il 3 Position piston on connecting rod Fig 49 CAUTION Ensure arrow on piston crown and the bearing cap numbers on the connecting rod are on the opposite side 4 Install piston pin Fig 49 5 Install clips in piston to retain piston pin Fig 49 80c6c8fe Fig 49 PISTON AND CONNECTING ROD ASSEMBLY PISTON PIN PISTON SNAP RING CONNECTING ROD ALIGNMENT NUMBERS CONNECTING ROD BOLT CONNECTING ROD BEARING CONNECTING ROD SNAP RING 6 Remove connecting rod from vice KJ PISTON RINGS INSTALLATION 1 Install rings on the pistons using a suitable ring expander Fig 50 Fig 50 PISTON RINGS INSTALLATION 2 Top compression ring is tapered and chromium plated The second ring is of the scraper type and must be installed with scraping edge facing bottom of the piston The third is an oil control ring Ring gaps must be positioned before inserting piston into the liners as follows 3 Top ring gap must be positioned at the 8 posi tion looking at the piston crown from above Fig 51 4 Second piston ring gap should be positioned at the 1 position Fig 51 5 Oil control ring gap should be positioned at the 2 position Fig 51 80c6c8ad Fig 51 PISTON RING GAP LOCATION 3 TOP COMPRESSION RING GAP POSITION 1 SECOND COMPRESSION RING GAP POSITION 2 OIL CONTROL RING GAP POSITION 6 When assembling pistons check that com
176. ine air filter element the Replace the engine air filter element air filter element Inspect idler pulleys and timing belt tensionert the Replace the engine timing belt mememe Drain and refi E S Replace the ftervater separator un rain and reiil the anster case Drain and refill the automatic transmission fluid and replace transmission main sump filter MAINTENANCE SCHEDULES 0 3 MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U S CANADA and MEXICO Continued Kilometers 110 000 km 120 000 km 130 000 km 140 000 km 150 000 160 000 km Change the engine oil and engine oil filter Inspect the ball joints Inspect the ball joints ball joints Inspect the engine air filter element Replace as necessary Replace the engine air filter element Inspect engine accessory drive belt Replace engine accessory drive belt Inspect the idler pulleys and timing belt tensionert Replace the engine timing belt Inspect the brake linings the brake Inspect the brake linings Drain and refill the front and rear axle fluid Replace the fuel filter water separator unit Flush and replace the engine coolant Drain and refill automatic transmission fluid and replace transmission filter s Inspection and service should also
177. ines at EGR solenoid 17 Connect camshaft position sensor boost pres sure intake air temperature sensor EGR solenoid and fuel pressure sensor electrical connectors 18 Install inner timing belt cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 19 Install timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION 20 Install outer timing belt cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 21 Remove crankshaft and both camshaft locking pins Refer to 9 ENGINE VALVE TIMING STAN DARD PROCEDURE 22 Install vibration damper 23 Install generator Refer to 8 ELECTRICAL CHARGING GENERATOR INSTALLATION 24 Install cooling fan support Refer to 7 COOLING ENGINE RADIATOR FAN INSTALLA TION 25 Install accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 26 Install cooling fan and fan drive viscous dutch assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH INSTALLATION 27 Refill cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 28 Install engine cover and bracket Refer to 9 ENGINE INSTALLATION 29 Connect negative battery cable ROCKER ARMS DESCRIPTION The rocker arms are made of stamped steel Fig 20 OPERATION The rocker arms are used as a link between the camshaft and valves As the camshaf
178. ins can be installed WARNING IF THE CAMSHAFT ALIGNMENT PINS CAN NOT BE INSTALLED AT THIS TIME REPEAT THE PROCEDURE FROM THE BEGINNING 13 Install the camshaft plugs 14 Install vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER INSTALLATION 15 Install the alternator 16 Install cooling fan support Refer to 7 COOLING ENGINE RADIATOR FAN INSTALLA TION 17 Install accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 18 Install cooling fan and fan drive viscous dutch assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH INSTALLATION 19 Install engine cover Refer to 9 ENGINE COVER INSTALLATION 20 Connect negative battery cable TIMING BELT CHAIN TENSIONER amp PULLEY REMOVAL 1 Disconnect negative battery cable 2 Remove engine cover Refer to 9 ENGINE COVER REMOVAL 3 Remove cooling fan and fan drive viscous dutch assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 4 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 5 Remove cooling fan support Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL 6 Remove vibration damper Refer to 9 BLOCK VIBRATION DAMPER REMOVAL 7 Remove timing belt outer cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 8 Loosen and remove timing bel
179. ionary while the input clutches drive others The 2C 4 and Low Reverse clutches are considered holding clutches The 2C and 4C clutches are located in the 4C retainer bulkhead Fig 6 while the Low Reverse clutch is located at the rear of the transmis sion case Fig 7 2 80 07032 Fig 6 2C and 4 Clutches 1 SEAL 8 REACTION PLATE 2 2C PISTON 9 SNAP RING 3 PLATE 10 RETURN SPRING 4 DISC 11 SEAL 5 2C BELLEVILLE SPRING 12 4C PISTON 6 SNAP RING 13 4C RETAINER BULKHEAD 7 SNAP RING SELECT KJ 21 29 AUTOMATIC TRANSMISSION 545RFE HOLDING CLUTCHES Continued A fim 1 0 AS TP Shi 227 808 2 78 Fig 7 Low Reverse Clutch 5 9 d 2 a g 0 2 929 1 2 nz 24262 on ee 00 oc E 2 lt de t ar 25 Ec ce 20852 Fu Seg 10 ON CO sf 10 CO 7 PISTON 21 30 AUTOMATIC TRANSMISSION 545RFE HOLDING CLUTCHES Continued OPERATION 2C CLUTCH The 2C clutch is hydraulically applied in second and fifth gear by pressurized fluid against the 2C piston When the 2C clutch is applied the reverse sun gear assembly is held or grounded to the trans mission case by holding the reaction planetary car rier 4C CLUTCH The 4C clutch is hydraulically applied in second prime and fourth gear by pr
180. is to be used as a strobe light 4 Block the air flow through the radiator Secure a sheet of plastic in front of the radiator or air con ditioner condenser Use tape at the top to secure the plastic and be sure that the air flow is blocked 5 Be sure that the air conditioner if equipped is turned off WARNING USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING 6 Start the engine and operate at 2400 rpm Within ten minutes the air temperature indicated on the dial thermometer should be up to 93 C 200 F Fan drive engagement should have started to occur at between 91 to 96 C 195 to 205 F Engage ment is distinguishable by a definite increase in fan flow noise roaring The timing light also will indi cate an increase in the speed of the fan 7 When the air temperature reaches 93 C 200 F remove the plastic sheet Fan drive disengage ment should have started to occur at between 62 to 85 C 145 to 185 F A definite decrease of fan flow noise roaring should be noticed If not replace the defective viscous fan drive unit REMOVAL 1 Disconnect negative battery cable NOTE The thermal viscous fan drive fan blade assembly is attached threaded to fan support 2 Remove fan blade viscous fan drive assembly from water pump using special tool 6958 spanner wrench by turnin
181. itted This usually occurs in cold weather with no fan or air flow to blow it away 1 Locate missing shields Repair or replace as necessary 2 Refer to the previous Temperature Gauge Reads High in these Diagnostic Charts Repair as necessary 3 Refer to Cooling System Fan in this group for diagnosis Repair as necessary 4 Clean undercoating as necessary 1 Occasional steam emitting from this area is normal No repair is necessary COOLANT ODOR COOLANT LEVEL CHANGES IN COOLANT TANK TEMPERATURE GAUGE IS IN NORMAL RANGE 1 Coolant color is not necessarily an indication of adequate corrosion or temperature protection Do not rely on coolant color for determining condition of coolant 1 Level changes are to be expected as coolant volume fluctuates with engine temperature If the level in the tank was between the HOT and COLD marks at normal engine operating temperature the level should return to within that range after operation at elevated temperatures 1 Refer to Coolant in this group for antifreeze tests Adjust antifreeze to water ratio as necessary 1 This a normal condition No repair necessary CHEMICAL CLEANING STANDARD PROCEDURE COOLING SYSTEM REVERSE FLUSHING CAUTION The cooling system normally operates at 97 to 110 kPa 14 to 16 psi pressure Exceeding this pressure may damage the radiator or hoses Reverse flushing of the cooling system is the forc ing of water through
182. k into the input clutch retainer Fig 13 14 Install the UD OD reaction plate lower flat snap ring Fig 17 The correct snap ring can be identified by the two tabbed ears 15 Install the UD OD reaction plate into the input clutch retainer The reaction plate is to be installed with the big step down 16 Install the UD OD reaction plate upper tapered snap ring with tapered side up 17 Install the input clutch assembly into Input Clutch Pressure Fixture 8260 Fig 18 Mount a dial indicator to the assembly push down on the clutch discs and zero the indicator against the underdrive clutch discs Fig 19 Apply 20 psi of air pressure to the underdrive clutch and record the dial indicator reading Measure and record UD clutch pack mea surement in four 4 places 90 apart Take average of four measurements and compare with UD clutch pack clearance specification The correct clutch clear ance is 0 84 1 54 mm 0 033 0 061 in The reaction plate is not selective If the clutch clearance is not within specification replace the reaction plate along with all the friction and steel discs 21 38 AUTOMATIC TRANSMISSION 545RFE INPUT CLUTCH ASSEMBLY Continued ENS TW 2 2 AS N Y ANN AN e KJ 808a2e68 Fig 17 Input Clutch Assembly Part BEARING NUMBER 3 OD HUB SHAFT SNAP RING WAVE REV OD REACTION PLATE BEARING NUMBER 4
183. l VM 1067 on injection pump sprocket as shown Fig 11 Secure flange to feet in injection pump sprocket with allen bolts supplied with tool 12 Screw the high pressure injection pump sprocket holding plate assembly into flange of VM 1067 Fig 12 Using left hand threaded bolt sup plied secure holding plate assembly to timing belt inner cover 13 Disconnect A C lines at compressor FUEL PUMP Continued 80c7596d Fig 10 VM 1067 FEET INSTALLATION OUTER TIMING BELT SEALING SURFACE TIMING BELT TIMING BELT SPROCKET FEET FOR SPECIAL TOOL VM 1067 INNER TIMING BELT COVER 14 Remove intake inlet tube at intake manifold 15 Remove high pressure injection pump to fuel rail high pressure line 16 Disconnect high pressure injection pump fuel pressure solenoid electrical connector 17 Disconnect fuel supply and return lines at high pressure injection pump Fig 13 18 Remove alternator to intake manifold bracket 19 Remove vacuum line bracket from intake manifold 20 Remove high pressure injection pump retain ing nuts and remove pump Fig 13 INSTALLATION WARNING HIGH PRESSURE LINES DELIVER DIE SEL FUEL UNDER EXTREME PRESSURE FROM THE INJECTION PUMP TO THE FUEL INJECTORS THIS MAY BE AS HIGH AS 1600BAR 23 200 PSI USE EXTREME CAUTION WHEN INSPECTING FOR HIGH PRESSURE FUEL LEAKS FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE SKIN CAUSIN
184. l the viscous fan almost touches the fan shroud 12 Raise vehicle on hoist 13 Support the front cradle assembly with a suit able lifting devise 14 Mark the front cradle to under body position to assure proper alignment during assembly 15 Remove both inner rail cradle alignment bolts in the front wheel housing 16 Loosen both power steering gear retaining bolts leave the retaining nuts on the bolts 17 Loosen both front cradle mounting bolts 18 Loosen both rear cradle mounting bolts 19 Remove all oil pan retaining bolts and lower oil pan Fig 60 20 Lower front cradle using the suitable lifting devise until enough dearance is obtained to remove the oil pan INSTALLATION 1 Clean oil pan and sealing surfaces Inspect oil pan and engine block 2 Install oil pan gasket and retaining bolts Fig 60 3 Torque oil pan bolts to 11 8 104 Ibs in 4 Raise the front cradle using a suitable lifting devise and align the cradle with the underbody marks made during the removal procedure 5 Torque the cradle mounting bolts to 122 N m 90 Ibs ft Torque the inner rail mounting bolts to 47 N m 35 Ibs ft engine support fixture special tool 6 DRIVELINE FRONT AXLE 9 46 ENGINE OIL PAN Continued ON 2 f 80cb3edb Fig 60 OIL PAN AND PRESSURE RELIEF VALVE pe SUPPORT ENGINE BLOCK RETAINING BOLT 2
185. lace tensioner if necessary 2 Replace pulley s 3 Remove foreign objects from grooves 4 Align component 5 Replace belt BELT BROKEN Note Identify and correct problem before new belt is installed 1 Incorrect belt tension 2 Tensile member damaged during belt installation 3 Severe misalignment 4 Bracket pulley or bearing failure 1 Replace Inspect Replace tensioner if necessary 2 Replace belt 3 Align pulley s 4 Replace defective component and belt KJ DRIVE BELT Continued CONDITION POSSIBLE CAUSES ACCESSORY DRIVE CORRECTION 7 13 NOISE Objectionable squeal squeak or rumble is heard or felt while drive belt is in operation 1 Incorrect belt tension 2 Bearing noise 3 Belt misalignment 4 Belt to pulley mismatch 5 Driven component induced 1 Inspect Replace tensioner if necessary 2 Locate and repair 3 Align belt pulley s 4 Install correct belt 5 Locate defective driven vibration component and repair TENSION SHEETING FABRIC FAILURE Woven fabric on outside circumference of belt has cracked or separated from body of belt stationary object fabric to age 3 Tension sheeting splice has fractured CORD EDGE FAILURE Tensile member exposed at edges of belt or separated from belt body 3 Pulley s out of tolerance 4 Insufficient adhesion between 1 Tension sheeting contacting 2 Excessive heat causing woven 1
186. lignment studs and install remaining retaining bolts Tighten retaining bolts finger tight 8 Torque cylinder head cover intake manifold retaining bolts following procedure below CYLINDER HEAD COVER INTAKE MANIFOLD TIGHTENING PROCEDURE e Alternate between bolts 11 and 16 to seat cyl inder head cover intake manifold on cylinder head Fig 19 Torque bolts to 7 N m e Torque all cylinder head cover intake manifold retaining bolts to 25 N m in numerical order starting with 1 and ending with 16 Fig 19 ENGINE 9 25 81068414 Fig 18 CYLINDER HEAD COVER ALIGNMENT STUDS VM 1066 1 CYLINDER HEAD COVER INTAKE MANIFOLD STUDS VM 1066 2 CYLINDER HEAD 80 5 0 Fig 19 CYLINDER HEAD MANIFOLD TIGHTENING SEQUENCE 9 Connect EGR tube at intake manifold inlet tube Torque clamp to 10 8 N m 10 Install turbo inlet tube retaining bolt at intake manifold Torque bolt to 27 5 N m 9 26 ENGINE CYLINDER HEAD COVER Continued 11 Connect oil separator outlet hose at separator 12 Install oil dipstick tube retaining bolt at intake manifold inlet Torque bolt to 10 N m 13 Install power steering pump reservoir in bracket 14 Install fuel rail Refer to 14 FUEL SYSTEM FUEL DELIVERY FUEL RAIL INSTALLATION 15 Install fuel injectors and fuel injector supply lines Refer to 14 FUEL SYSTEM FUEL INJ EC TION FUEL INJ ECTOR INSTALLATION 16 Connect vacuum l
187. lling belt 3 Install timing belt on crankshaft hub and fix it with special tool VM 1074 then around high pres sure injection pump idler pulley intake camshaft gear exhaust camshaft gear idler pulley and water pump gear 4 Adjust the timing belt tensioner turn it clock wise lining up the center notch with the aluminum cover dowel pin Tighten the retaining bolt to 28N m Refer to 9 ENGINE VALVE TIMING TMNG BELT CHAIN TENSIONER amp PULLEY ADJ UST MENTS NOTE To uniform the belt tension with special tool VM 1055 slightly turn the intake camshaft pulley counterclockwise KJ ENGINE 9 57 TIMING BELT CHAIN AND SPROCKET S Continued 5 Tighten the camshaft gear bolts to 60N m while holding the gears with special tool VM 1055 6 Remove intake and exhaust alignment pins 7 Torque camshaft gear bolts to 108N m while holding gears with special tool VM 1055 Refer to 9 TIMING STANDARD PROCE DURE 8 Remove engine locking pin from engine block 9 Install timing belt outer cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION WARNING IF CAMSHAFT COVER WAS REMOVED WAIT 30 MINUTES BEFORE ROTATING CRANK SHAFT 10 Rotate the engine clockwise 2 revolutions looking at engine from the belt side 11 Carefully line up the crankshaft hub painted mark with the oil pump cover mark 12 Check that the intake and exhaust camshaft alignment p
188. lt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 4 Remove cooling fan support Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL 5 Remove vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER REMOVAL 6 Remove timing belt outer cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 7 Remove timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL KJ 8 Remove timing belt inner cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 9 Remove front engine cover ENGINE ENGINE BLOCK ENGINE REMOVAL 10 Remove crankshaft sprocket Fig 65 11 Remove oil pump retaining bolts and remove pump from engine block Fig 65 Refer to 9 COVER 80 9048 Fig 65 OIL PUMP AND VACUUM PUMP 1 VACUUM PUMP 2 CRANKSHAFT SPROCKET 3 OIL PUMP 4 ENGINE BLOCK 5 CRANKSHAFT INSTALLATION INSTALLATION OIL PUMP PICKUP TUBE 1 Lubricate o ring on oil pump pickup tube with engine oil 2 Install pickup tube in engine block and install retaining bolt Torque bolt to 32 4N m Fig 64 3 Install oil pan Refer to 9 ENGINE LUBRI CATION OIL PAN INSTALLATION 4 Refill engine oil to proper level 5 Connect negative battery cable INSTALLATION OIL PUMP 1 Lubricate pump rotor with engine oil 2 Install oil pump in bore in engine block OIL PUMP Con
189. lter cap 3 Remove two fuel lines from the water separator Fig 2 Loosen retaining clamps and slide the hose from barbed fittings Fig 2 4 Remove fuel water separator retaining nuts and carefully slide separator off its mounting studs Fig 3 Use care not to spill excess fuel or damage electrical connections located on the bottom of the assembly 5 Disconnect electrical connectors located on the bottom of the separator assembly 6 Remove fuel water separator from the engine bay KJ FUEL DELIVERY 14 5 FUEL FILTER WATER SEPARATOR Continued r 1 7 5 2 2 Pi Fig 1 FUEL FILTER WATER SEPARATOR 1 FUEL FILTER WATER SEPARATOR ASSEMBLY 2 WATER IN FUEL SENSOR 3 FUEL HEATER INSTALLATION 1 Position fuel water separator in the engine bay and connect the electrical connectors located on the bottom of the separator assembly 2 Install fuel water separator on its mounting studs and install the retaining nuts Fig 3 3 Install two fuel lines on the water separator Fig 2 4 Prime fuel system using the fuel priming plunger Refer to 14 FUEL SYSTEM STANDARD PROCEDURE 5 Connect negative battery cable 80ceddce 80cdb266 Fig 2 FUEL FILTER WATER SEPARATOR FUEL LINES HOSE CLAMP HOSE CLAMP 1 2 3 FUEL INLET LINE TO FUEL FILTER WATER SEPARATOR 4 FUEL OUTLET LINE TO INJECTION PUMP 80cdb3a6 Fig 3 FUEL FILTER WATER SEPARATOR
190. lug relays These relays are located in the Power Distribution Center PDC in the engine compartment Fig 7 80d35f6c Fig 7 GLOW PLUG RELAYS COMPRESSOR CLUTCH RELAY VISCOUS HEATER RELAY ASD RELAY GLOW PLUG 3 4 RELAY 2 CLUTCH SWITCH OVERRIDE RELAY GLOW PLUG 1 2 RELAY 1 STARTER RELAY FUEL HEATER RELAY OPERATION When the ignition key switch is place in the ON position a signal is sent to the ECM relating current engine coolant temperature This signal is sent from the engine coolant temperature sensor After receiving this signal the ECM will determine if when and for how long of a period the glow plug relays should be activated This is done before dur ing and after the engine is started Whenever the glow plug relays are activated it will control the 12 volt 100 amp circuit for the operation of the four glow plugs Each relay control two glow plugs The Glow Plug lamp is tied to this circuit Lamp operation is also controlled by the ECM With a cold engine the glow plug relays and glow plugs may be activated for a maximum time of 200 seconds Refer to the following Glow Plug Control chart for a temperature time comparison of the glow plug relay operation In this chart Pre Heat and Post Heat times are mentioned Pre Heat is the amount of time the glow plug
191. m perature electrical connectors 43 Remove turbocharger outlet to charge air cooler hose 44 Remove cylinder head bolts 45 Remove cylinder head assembly from engine block Fig 9 CLEANING Thoroughly clean the engine cylinder head and inder block mating surfaces Clean the intake and exhaust manifold and engine cylinder head mating surfaces Remove all gasket material and carbon Check to ensure that no coolant or foreign material has fallen into the tappet bore area Remove the carbon deposits from the combustion chambers and top of the pistons INSPECTION Use a straightedge and feeler gauge to check the flatness of the engine cylinder head and block mating surfaces The minimum cylinder head thickness is 89 95mm 3 541 in INSTALLATION 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 ENGINE 9 19 80d368c5 Fig 9 CYLINDER HEAD ASSEMBLY CYLINDER HEAD BOLT GLOW PLUG COOLANT TEMPERATURE SENSOR CYLINDER HEAD ALIGNMENT DOWEL GLOW PLUG HARNESS CYLINDER LINER CYLINDER BLOCK CYLINDER HEAD GASKET CYLINDER HEAD 0 ROCKER ARM ASSEMBLIES 1 Clean and inspect ga
192. m 0 61 0 70 Fit Gasket 30 80 81 00 mm umber 1 42 1 notc or hole Head Stand Down 171383 Fr Gasket T0834 mm Number 1 52 2 notches 0 99 1 25 mm or holes Stem Diameter 59525970 mm 5 942 5 860 mm 9 8 ENGINE 2 5L 2 8L TURBO DIESEL Continued 6 00 6 012 mm DESCRIPTION SPECIFICATION ois LUBRICATION Pressure Relief Valve 6 50 bar Opens Pressure Relief Valve 51 5 mm Spring Free Length OIL PUMP Outer Rotor End Float 0 060 0 160 mm Inner Rotor End Float 0 060 0 160 mm Outer Rotor to Body 0 130 0 240 mm Diameter Clearance Rotor Body to Drive Gear 0 90 1 50 mm Clearance pump not fitted 2 5L 2 8L DIESEL TORQUE SPECIFICATIONS Nm or Pump Bots os Crankshaft Gear Bors 8 Crankshaft Position 10 8 Sensor Bolts Flywheel Bolts 2 5L 3 stages 50N m 37 18 clockwise then 25N m plus 90 cross sequence Flywheel Bolts 2 8L 3 stages 50N m 37 18 clockwise then 25N m plus 60 cross sequence Oylinder Head Bolts Refer to the Service Procedure Reluctor Whee Balls Rear Main Bearing 27 5 21 Support Bolts Oil Cooler to Engine Block 47 1 35 Bolt 18 162 510 595 5 SPECIFICATIONS TORQUE 240 Oil Cooler Mounting Stud Water Rousing 247 5 Connecting Rod Bolts Refer to the Service Procedure 86 KJ
193. ment The cooling system 15 pressurized and uses a centrifugal water pump to circulate coolant throughout the system A separate and remotely mounted pressurized coolant tank using a pressure vent cap is used COOLING SYSTEM COMPONENTS The cooling system consists of e Charge Air Cooler e Electric Cooling Fans aluminum core radiator with plastic side tanks e A separate pressurized coolant tank e A pressure vent cap on the coolant tank e Fan shroud e Thermostat e Coolant e Low coolant warning lamp e Coolant temperature gauge e Water pump e Hoses and hose clamps COOLING 2 5L 2 8L TURBO DIESEL 7 1 page STANDARD PROCEDURE COOLING SYSTEM REVERSE FLUSHING 7 CLEANING 8 INSPECTION X eed 8 SPECIFICATIONS SPECIFICATIONS COOLING SYSTEM 8 SPECIFICATIONS TORQUE 8 ACCESSORY DRIVE 9 ENGINE 202222222224 599 9 eared 16 DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING COOLING SYSTEM FLOW CHECK To determine whether coolant is flowing through the cooling system use the following procedures 1 If engine is cold idle engine until normal oper ating temperature is reached Then feel the upper radiator hose If it is hot coolant is circulating WARNING DO NOT REMOVE THE COOLING SYS TEM PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM
194. mmer handle At the same time guide connecting rod into position on connecting rod journal 7 Install connecting rod caps Fig 53 Install rod bolts and torque to 10 88 Ibs in Torque bolts ENGINE 9 41 the next stage to 30N m 22 plus 60 Then torque to 88N m 65 ft Ib 80c6e51b Fig 53 PISTON AND CONNECTING ROD INSTALLATION PISTON AND CONNECTING ROD ASSEMBLY FOUR DIGIT NUMBER CONNECTING ROD BOLT FOUR DIGIT NUMBER 8 Install cylinder head Refer to 9 ENGINE CYLINDER HEAD INSTALLATION 9 Install balance shaft assembly Refer to 9 TIMING BALANCE SHAFT INSTALLATION 10 Install oil pump pickup tube Refer to 9 ENGINE LUBRICATION OIL PUMP INSTALLA TION 11 Install oil pan Refer to 9 ENGINE LUBRI CATION OIL PAN INSTALLATION 12 Connect negative battery cable VIBRATION DAMPER REMOVAL 1 Disconnect negative battery cable 2 Remove viscous cooling fan and shrowd Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 3 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 9 42 ENGINE VIBRATION DAMPER Continued 4 Remove vibration damper retaining bolts and damper Fig 54 80d39d51 Fig 54 VIBRATION DAMPER 1 VIBRATION DAMPER CRANKSHAFT PULLEY RETAINING BOLTS 2 VIBRATION DAMPER CRANKSHAFT PULLEY 3 IDLER PULLEY INSTALLATION 1 Install
195. moisture water from doing so Moisture collects at the bottom of the canister Refer to the maintenance schedules for the recom mended fuel filter replacement intervals For draining of water from canister refer to Fuel Filter Water Separator Removal l nstallation section A Water In F uel WIF sensor is part of the fuel fil ter cap Refer to Water In Fuel Sensor Description Operation The fuel heater is also part of the fuel filter cap Refer to Fuel Heater Description Operation KJ page FUEL INJECTION PUMP DESCRIPTION 2 2 24444 10 REMOVAL eR 10 INSTALLATION 11 FUEL TANK MODULE DESCRIPTION eR E 13 REMOVAL a dia eee 13 INSTALLATION 14 FUEL LEVEL SENDING UNIT SENSOR DESCRIPTION ye gee reese ede ae 15 OPERATION Lenses shames sade de 15 DIAGNOSIS AND TESTING FUEL LEVEL SENDING UNIT 15 REMOVAL RE 15 INSTALLATION 15 FUEL HEATER DESCRIPTION 4404 16 OPERATION 16 REMOVAL s l2 p ERE 16 INSTALLATION 16 FUEL PRESSURE SOLENOID DESGRIPTION yank Pa eee neers 17 OPERATION he EE Y RS 17 REMOVAL 1 Disconnect negative battery cable 2 Drain fuel filter water separator assembly by loosening drain at bottom of fuel fi
196. n the dutch will engage after the shift to fourth gear and above approximately 72 km h 45 mph If the control switch is in the OFF position the dutch will engage after the shift to AT STALL A CRUISE 80bfe26e Fig 23 Stator Operation 1 DIRECTION STATOR WILL FREE WHEEL DUE TO OIL PUSHING ON BACKSIDE OF VANES 2 FRONT OF ENGINE 3 INCREASED ANGLE AS OIL STRIKES VANES 4 DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING AGAINST STATOR VANES third gear at approximately 56 km h 35 mph at light throttle The TCM controls the torque converter by way of internal logic software The programming of the soft ware provides the TCM with control over the L R CC 21 42 AUTOMATIC TRANSMISSION 545RFE TORQUE CONVERTER Continued Solenoid There are four output logic states that can be applied as follows e NoEMCC e Partial EMCC e Full EMCC Gradual to no Under conditions the L R Solenoid is OFF There are several conditions that can result in NO EMCC operations No EMCC can be initiated due to a fault in the transmission or because the TCM does not see the need for EMCC under current driving conditions PARTIAL EMCC Partial EMCC operation modulates the L R Sole noid duty cycle to obtain partial torque converter clutch application Partial EMCC operation is main tained until Full EMCC is called for and actuated During Partial EMCC some slip does occur Pa
197. n and refill automatic transmission fluid and replace transmission filter s Inspection and service should also be performed anytime a malfunction is observed or suspected Retain all receipts t Replace if there is superficial wear bearing dear ance or evident grease leak WARNING You be badly injured working on around a motor vehicle Do only that service work for which you have the knowledge and the right equipment If you have any doubt about your ability to perform a service job take your vehicle to a competent mechanic KJ COOLING 2 5L 2 8L TURBO DIESEL TABLE OF CONTENTS page COOLING 2 5L 2 8L TURBO DIESEL DESCRIPTION COOLING SYSTEM 1 DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING COOLING SYSTEM FLOW CHECK 1 DIAGNOSIS AND TESTING COOLING SYSTEM AERATION 1 DIAGNOSIS AND TESTING COOLING SYSTEM LEAK 8 2 DIAGNOSIS AND TESTING ON BOARD DIAGNOSTICS 2 DIAGNOSIS AND TESTING COOLING 5 5 3 COOLING 2 5L 2 8L TURBO DIESEL DESCRIPTION COOLING SYSTEM The cooling system regulates engine operating tem perature It allows the engine to reach normal oper ating temperature as quickly as possible maintains normal operating temperature and prevents over heating The cooling system also provides a means of heat ing the passenger compart
198. n cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PRO CEDURE 4 Disconnect upper radiator hose and bypass hoses at thermostat housing 5 Remove thermostat housing retaining bolts support bracket 2 8L and housing from cylinder head discard gasket Fig 7 KJ ENGINE 7 21 ENGINE COOLANT THERMOSTAT Continued 8105d55a Fig 6 THERMOSTAT HOUSING THERMOSTAT HOUSING GASKET 1 2 THERMOSTAT HOUSING 3 TURBOCHARGER OIL SUPPLY LINE BANJO BOLT 4 THERMOSTAT HOUSING RETAINING BOLTS 5 BRASS WASHER 6 EXHAUST MANIFOLD GASKET 7 EXHAUST MANIFOLD 8 EXHAUST MANIFOLD HEATSHIELD 9 EXHAUST MANIFOLD HEATSHIELD RETAINING BOLTS 10 OIL RETURN HOSE 11 HOSE CLAMPS 12 EXHAUST MANIFOLD RETAINING NUTS 13 TURBOCHARGER DOWNPIPE STUDS 14 TURBOCHARGER DOWN PIPE GASKET 15 TURBOCHARGER DOWNPIPE 16 TURBOCHARGER DOWNPIPE RETAINING NUT INSTALLATION 1 Clean old gasket material from cylinder head and thermostat housing 2 Install thermostat housing with gasket and support bracket 2 8L to cylinder head Fig 7 Torque bolts to 27 5N m 3 Connect coolant bypass hose and upper radia tor hose to thermostat housing 4 Refill cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 80 52 5 Fig 7 THERMOSTAT HOUSING ASSEMBLY THERMOSTAT HOUSING GASKET THERMOSTAT HOUSING RETAINING BOLTS CYLINDER HEAD CYLINDER HEAD COVER INTAK
199. n system again until water runs clear INSPECTION After performing cleaning flush procedure inspect all hoses clamps and connections for deterio ration and leaks Inspect radiator and heater core for leaks SPECIFICATIONS SPECIFICATIONS COOLING SYSTEM CAPACITY SPECIFICATIONS DESCRIPTION SPECIFICATION Cooling System With 16 6 Liters 17 5 qts Auxiliary Heater Cooling System With Out 13 8 Liters 14 6 qts Auxiliary Heater SPECIFICATIONS TORQUE 2 5L 2 8L DIESEL TORQUE SPECIFICATIONS DESCRIPTION Accessory Drive Belt Idler Bolt Accessory Drive Belt Tensioner Bolt Cooling Fan Support Bolts Water Pump Housing Nuts Kj ACCESSORY DRIVE 7 9 ACCESSORY DRIVE TABLE OF CONTENTS page page ACCESSORY DRIVE OPERATION ACCESSORY DRIVE BELT 11 SPECIFICATIONS ACCESSORY BELT DIAGNOSIS AND TESTING ACCESSORY TENSION e m e UR hn qas 9 DRIVE BELT eR Ra 11 BELT TENSIONERS REMOVAL HR SERERE 13 DESCRIPTION seg ginea nda eee 9 INSTALLATION 13 OPERATION repas e E 9 IDLER PULLEYS REMOVAL iinet are RR ates i RR RC ata 10 REMOVAL vss RR ER a 14 INSTALLATION 10 INSTALLATION 15 DRIVE BELT DESCRIPTION 95 59 deeded ey 11 ACCESSOR
200. n the engine is cold then the engine is warmed up to a certain temperature and finally the engine temperature falls to a normal operating tem perature then the key is turned off Certain criteria must be met for a DTC to be entered into ECM memory The criteria may be a specific range of engine rpm engine or fuel tempera ture and or input voltage to the ECM A DTC indi cates that the ECM has identified an abnormal signal in a circuit or the system There are several operating conditions that the ECM does not monitor and set a DTC for Refer to the following Monitored Circuits and Non Monitored Circuits in this section ECM MONITORED SYSTEMS The ECM can detect certain problems in the elec trical system Open or Shorted Circuit The ECM will not distinguish between an open or a short to ground however the ECM can determine if there is excessive current on a circuit such as a short to voltage or a decrease in component resistance Output Device Current Flow The ECM senses whether the output devices are electrically connected If there is a problem with the circuit the ECM senses whether the circuit is open shorted to ground or shorted to voltage 25 1 SPECIFICATIONS TORQUE 2 ON BOARD DIAGNOSTICS 3 EXHAUST GAS RECIRCULATION 7 Fuel Pressure High fuel pressure is controlled by the fuel injection pump fuel pressure solenoid and fuel pressure sensor
201. n valve guide is 040 to 075 mm 0015 to 0029 in Clearance of exhaust valve stem in valve guide is 060 to 093 mm 0023 to 0036 in 4 If valve stem clearance in valve guide exceeds tolerances new valve guides must be installed CYLINDER HEAD Continued STANDARD PROCEDURE MEASURING PISTON PROTRUSION 1 Use special tool VM 1010 with dial indicator special tool VM 1013 Fig 6 81067965 Fig 6 PISTON PROTRUSION 2 Bring the piston of cylinder no 1 exactly to top dead center 3 Zero the dial indicator on the cylinder block mating surface 4 Setup the dial indicator on the piston crown above the center of the piston pin 5mm 1 8 in from the edge of the piston and note the measurement 5 Repeat the procedure with the rest of the cyl inders 6 Establish the thickness of the steel gasket by averaging the four piston potrusion readings Measure Dimension mm 0 49 0 60 Cylinder Head Gasket 1 32 Thickness mm No Holes or Notches Piston Clearance mm 0 72 0 83 0 61 0 70 1 42 1 Hole or Notch 0 72 0 81 Measure Dimension mm Cylinder Head Gasket Thickness mm Piston Clearance mm Measure Dimension mm 0 71 0 83 Cylinder Head Gasket 1 52 Thickness mm 2 Holes or Notches 0 69 0 81 Piston Clearance mm ENGINE 9 17 REMOVAL 1 Disconnect negative battery cable 2 Remove engine cover and bracket Refer to 9 ENGINE COVER REMOVAL 3 Drain cooling
202. nal leaks that can be deter mined by removing the oil dipstick If water globules appear intermixed with the oil it will indicate an internal leak in the engine If there is an internal leak the engine must be disassembled for repair DIAGNOSIS AND TESTING ON BOARD DIAGNOSTICS OBD COOLING SYSTEM RELATED DIAGNOSTICS The Engine Control Module ECM has been pro grammed to monitor certain cooling system compo nents If the problem is sensed in a monitored circuit often enough to indicated an actual problem a DTC is stored The DTC will be stored in the ECM mem ory for eventual display to the service technician Refer to 25 EMISSIONS CONTROL DESCRIP TION ACCESSING DIAGNOSTIC TROUBLE CODES To read DTC s and to obtain cooling system data Refer to 25 EMISSIONS CONTROL DESCRIP TION ERASING TROUBLE CODES After the problem has been repaired use the DRBIII scan tool to erase a DTC Refer to the appropriate Powertrain Diagnostic Procedures ser vice information for operation of the DRBIII scan tool COOLING 2 5L 2 8L TURBO DIESEL 7 3 COOLING 2 5L 2 8L TURBO DIESEL Continued DIAGNOSIS AND TESTING COOLING SYSTEM Establish what driving conditions caused the com plaint Abnormal loads on the cooling system such as the following may be the cause 1 PROLONGED IDLE VERY HIGH AMBIENT TEMPERATURE SLIGHT TAIL WIND AT IDLE SLOW TRAFFIC TRAFFIC JAMS HIGH SPEED OR STEEP GRADES e Idle wit
203. nap ring from the input clutch retainer 11 Remove the UD OD reaction plate tapered snap ring from the input clutch retainer 12 Remove the UD OD reaction plate from the input clutch retainer 13 Remove the UD OD reaction plate flat snap ring from the input clutch retainer Fig 10 14 Remove the underdrive clutch pack from the input clutch retainer Fig 12 15 Using Spring Compressor 8251 compress the UD OD balance piston and remove the snap ring from the input clutch hub Fig 11 16 Remove the UD OD balance piston and piston return spring from the input clutch retainer Fig 12 17 Remove the underdrive piston from the input clutch retainer Fig 12 NOTE Both the UD OD balance piston and the underdrive piston have seals molded onto them If the seal is damaged do not attempt to install a new seal onto the piston The piston seal must be replaced as an assembly 18 Remove the input clutch retainer tapered snap ring 19 Separate input clutch retainer from input dutch hub 20 Separate OD reverse piston from input dutch hub retainer Fig 12 KJ 80c07426 Fig 11 Compressing UD OD Balance Piston Using Tool 8251 1 PRESS 2 TOOL 8251 3 BALANCE PISTON 21 Remove all seals and o rings from the input shaft and input hub The o rings on the input hub are color coded Be sure to make note of which o ring belongs in which location INPUT CLUTCH ASSEMBLY Continued AUTO
204. nd the injector nozzle DO NOT lubricate area around injec tor nozzle The injector may become restricted with debris 14 24 FUEL INJECTION FUEL INJ ECTOR Continued 80cf4d1e Fig 12 FUEL SYSTEM COMPONENTS FUEL INJECTOR RETURN LINE FUEL INJECTOR RETAINING BOLT INJECTOR RETAINER HIGH PRESSURE FUEL LINE FUEL RAIL RETAINING BOLT FUEL RAIL RETURN LINE FUEL PRESSURE SENSOR FUEL RAIL 1 2 3 4 5 6 7 8 9 10 BOOST PRESSURE INTAKE AIR TEMPERATURE SENSOR NOTE Be sure the copper washer is installed on end of injector before installing in cylinder head 1 Apply antiseize compound to injector body 2 Install fuel injector in cylinder head 3 Install fuel injector high pressure line Refer to 14 FUEL SYSTEM WARNING Fig 12 4 Install fuel injector retainer and bolt Fig 12 Torque bolt to 32 4 N m 5 Install fuel return line to injector Fig 12 6 Connect fuel injector electrical connector 7 Install engine cover and bracket assembly Refer to 9 ENGINE COVER INSTALLATION 8 Connect negative battery cable KJ FUEL PRESSURE SENSOR DESCRIPTION WARNING HIGH PRESSURE FUEL LINE DELIVER DIESEL FUEL UNDER EXTREME PRESSURE FROM THE INJECTION PUMP TO THE FUEL INJECTORS THIS MAY BE AS HIGH AS 1600BAR 23 200PSI USE EXTREME CAUTION WHEN INSPECTING FOR HIGH PRESSURE FUEL LEAKS FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE SKIN CAUSING PERSONAL IN
205. nected 2 Disconnect and isolate the battery negative cable Connect the battery charger leads Some bat tery chargers are equipped with polarity sensing cir cuitry This circuitry protects the battery charger and the battery from being damaged if they are improp erly connected If the battery state of charge is too low for the polarity sensing circuitry to detect the battery charger will not operate This makes it appear that the battery will not accept charging cur rent See the instructions provided by the manufac turer of the battery charger for details on how to bypass the polarity sensing circuitry 3 Battery chargers vary in the amount of voltage and current they provide The amount of time required for a battery to accept measurable charging current at various voltages is shown in the Charge Rate Table If the charging current is still not mea surable at the end of the charging time the battery is faulty and must be replaced If the charging cur rent is measurable during the charging time the bat tery may be good and the charging should be completed in the normal manner ENGINE SYSTEMS 8F 3 SPIRAL PLATE BATTERY CHARGE RATE TABLE votage 14 4 volts maximum up to 10 minutes 13 0 to 14 volts up to 20 minutes 12 9 volts or less up to 30 minutes CHARGING TIME REQUIRED The time required to charge a battery will vary depending upon the following factors e Battery Capacity A completely discharged heavy duty
206. ner from bracket Fig 3 within approximately 3 mm 1 8 in of indexing mark Belt is considered new if it has been used 15 minutes or less If this specification cannot be met check for e The wrong belt being installed incorrect length width e Worn bearings on an engine accessory A C com pressor power steering pump water pump idler pul ley or generator e A pulley on an engine accessory being loose e Misalignment of an engine accessory e Belt incorrectly routed REMOVAL 1 Disconnect negative battery cable 80d3a7f9 Fig 3 BELT TENSIONER ASSEMBLY ACCESSORY BELT TENSIONER RETAINING BOLT POWER STEERING PUMP PULLEY BELT TENSIONER BRACKET POWER STEERING PUMP POWER STEERING PUMP RETAINING BOLTS POWER STEERING PUMP PULLEY RETAINING BOLTS INSTALLATION 1 Install belt tensioner on bracket Fig 3 Torque retaining bolt to 47 1N m 2 Install accessory drive belt Fig 2 Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 80cdd35c Fig 2 ACCESSORY BELT ROUTING 3 Connect negative battery cable IDLER PULLEY GENERATOR IDLER PULLEY AIC COMPRESSOR COOLING FAN SUPPORT VIBRATION DAMPER BELT TENSIONER POWER STEERING PUMP ACCESSORY DRIVE BELT 0 VISCOUS HEATER KJ DRIVE BELT DESCRIPTION The accessory drive belt is a serpentine type belt Fig 4 Satisfactory performance of thes
207. ng belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL 8 Remove timing belt inner cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL NOTE Crankshaft hub has left hand thread 9 Remove crankshaft hub 10 Remove front engine cover Fig 58 INSTALLATION 1 Clean engine block and front engine cover seal ing surfaces 2 Apply a continous 3mm bead of Silicone Sealer to cover install within 10 minutes Torque bolts to 11 8N m Fig 58 3 Install crankshaft hub Torque bolt to 304N m 4 Install timing belt inner cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 5 Install timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION 6 Install timing belt outer cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 7 Install vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER INSTAL LATION 8 Install cooling fan support Refer to 7 COOL ING ENGINE RADIATOR FAN INSTALLATION 9 Install accessory drive belt Refer to 7 COOL ING ACCESSORY DRIVE DRIVE BELTS INSTAL LATION KJ 81068641 Fig 58 FRONT ENGINE COVER CRANKSHAFT HUB RETAINING BOLT FRONT COVER RETAINING BOLTS FRONT COVER ENGINE BLOCK FRONT ENGINE COVER ALIGNMENT DOWEL CRANKSHAFT HUB 10 Install co
208. ng bolts 22 Accessing bolts through the pump pulley install the power steering pump and retaining bolts 23 Install accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 24 Install coolant reservoir and connect hoses 25 Install coolant reservoir retaining nuts 26 Install high side refrigerant line on compres Sor 27 Install charge air cooler hose on intake mani fold 28 Install cooling module assembly in the engine bay 29 Install power steering cooler and retaining bolts and clip the air deflectors on both sides of the radiator cooling module assembly 30 Install condenser assembly and bolts 31 Install low side refrigerant line and retaining nut 32 Connect coolant reservoir hose on radiator 33 Connect engine coolant hoses on engine 34 Connect charge air cooler hoses on charge air cooler 35 Install fan shroud with cooling fan assembly inside the shroud and install the shroud retaining bolts 36 Connect cooling fan and fan drive viscous dutch assembly to fan support 37 Install high side refrigerant line and retaining nut retaining 9 6 ENGINE KJ ENGINE 2 5L 2 8L TURBO DIESEL Continued 38 Install upper radiator support bracket and retaining bolts 39 Connect high side refrigerant line on the upper radiator support bracket 40 Charge refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROC
209. ngine cover and bracket Refer to 9 ENGINE REMOVAL 3 Drain cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 4 Remove cooling fan and fan drive viscous clutch assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 5 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 6 Remove cooling fan support Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL 7 Remove vibration damper 8 Remove generator Refer to 8 ELECTRICAL CHARGING GENERATOR REMOVAL CAMSHAFT S Continued CAUTION Before removing the cylinder head cover intake manifold or timing belt the engine must put at 90 after TDC Failure to do so could result in valve and or piston damage during reassembly Refer to 9 ENGINE VALVE TIMING STANDARD PROCEDURE 9 Remove timing belt outer cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 10 Remove timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL 11 Remove timing belt inner cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 12 Remove cylinder head cover intake manifold Refer to 9 ENGINE CYLINDER HEAD CYLIN DER HEAD COVER S REMOVAL 13 With cylinder head cover intake manifold on work bench remove plugs at rear of cylinder head cover intake manifold 14 Remove camshaft oil seals Fig 1
210. nkcase TURBOCHARGER Continued 80c073cf Fig 10 Turbocharger Oil Supply and Drain 1 BEARINGS 2 OIL SUPPLY FROM ENGINE BLOCk 3 OIL RETURN TO OIL The most common turbocharger failure is bearing failure related to repeated hot shutdowns with inad equate cool down periods A sudden engine shut down after prolonged operation will result in the transfer of heat from the turbine section of the tur bocharger to the bearing housing This causes the oil to overheat and break down which causes bearing and shaft damage the next time the vehicle is started Letting the engine idle after extended operation allows the turbine housing to cool to normal operat ing temperature The following chart should be used as a guide in determining the amount of engine idle time required to sufficiently cool down the turbo charger before shut down depending upon the type of driving and the amount of cargo EXHAUST SYSTEM AND TURBOCHARGER 11 7 TURBOCHARGER COOL DOWN CHART Driving Turbo charger Idle Time in minutes Before Shut Down Condition Tempera Load ture Highway Medium Warm Speeds City Traffic Max Warm GCWR Highway Max Warm Speeds GCWR Uphill Grade Max GCWR REMOVAL 1 Disconnect negative battery cable 2 Remove engine cover Refer to 9 ENGINE REMOVAL 3 Remove air cleaner assembly Fig 11 4 Remove air inlet hose from turbocharger Fig 11
211. not be tampered with The wastegate bracket is an integral part of the turbocharger Tam pering with the wastegate components can reduce durability by increasing cylinder pressure and ther mal loading due to incorrect inlet and exhaust man ifold pressure Poor fuel economy and failure to meet regulatory emissions laws may result Increas ing the turbocharger boost WILL NOT increase engine power The turbocharger is an exhaust driven super charger which increases the pressure and density of the air entering the engine With the increase of air entering the engine more fuel can be injected into the cylinders which creates more power during com bustion The turbocharger assembly consists of four 4 major component systems Fig 7 Fig 8 e Turbine section e Compressor section e Bearing housing e Wastegate 80656650 Fig 7 Turbocharger Operation TURBINE SECTION EXHAUST GAS BEARING HOUSING COMPRESSOR SECTION INLET AIR COMPRESSED AIR TO ENGINE EXHAUST GAS EXHAUST GAS TO EXHAUST PIPE OPERATION Exhaust gas pressure and energy drive the tur bine which in turn drives a centrifugal compressor that compresses the inlet air and forces the air into the engine through the charge air cooler and plumb ing Since heat is a by product of this compression the air must pass through a charge air cooler to cool the incoming air and maintain power and efficiency Increasing air flow
212. ns that it will not generate heat when the temperature is above a cer tain value When the temperature is below 7 C 45 F the resistance of the PTC element is lowered and allows current to flow through the fuel heater ele ment warming the fuel When the temperature is above 29 C 85 F the PTC element s resistance rises and current flow through the heater element stops KJ Voltage to operate the fuel heater is supplied from the ignition key switch and through the fuel heater relay Refer to the following Fuel Heater Relay for additional information The fuel heater and fuel heater relay are not controlled by the Engine Control Module ECM REMOVAL 1 Disconnect negative battery cable 2 Disconnect fuel heater and WIF sensor electri cal connectors 3 Drain fuel filter water separator assembly into a suitable container by loosening drain at bottom of fuel filter cap 4 Remove fuel filter cap from bottom of filter assembly 5 Remove fuel heater retaining screws and remove heater assembly from fuel filter cap Fig 20 80cf eb5 Fig 20 FUEL HEATER ASSEMBLY 1 FUEL FILTER CAP ASSEMBLY 2 FUEL HEATER RETAINING SCREWS 3 FUEL HEATER ASSEMBLY INSTALLATION 1 Install fuel heater assembly in fuel filter cap Tighten retaining screws 2 Install fuel filter cap on fuel filter assembly 3 Connect fuel heater and WIF sensor electrical connectors 4 Prime fuel system using the fuel p
213. o Low A C Clutch Relay Circuit Open Circuit A C Clutch Relay Circuit Short Circuit Sensor Reference Voltage B CKT Voltage Too Low Sensor Reference Voltage B CKT Voltage Too High ECM PCM Relay Control Circuit Shuts Off Too Early ECM PCM Relay Control Circuit Shuts Off Too Late Brake Switch Signal Circuits Incorrect Can Message Brake Switch Signal Circuits Plausibility With Redundant Contact Fuel Rail Pressure Malfunction Small Leakage Detected Fuel Rail Pressure Malfunction Small Leakage Detected 25 6 ON BOARD DIAGNOSTICS ON BOARD DIAGNOSTICS Continued Generic Scan Tool Code DRB Scan Tool Display P1131 Fuel Pressure Solenoid Open Circuit Fuel Pressure Solenoid Short Circuit P1206 Calculated Injector Voltage 1 Too Low Calculated Injector Voltage 2 Too Low P1511 Battery Sense Line 1 Voltage Too High Battery Sense Line 1 Voltage Too Low P1601 Capacitor Voltage 1 Voltage Too High Capacitor Voltage 1 Voltage Too Low P1602 Capacitor Voltage 2 Voltage Too High Capacitor Voltage 2 Voltage Too Low P1605 Ignition Switch Plausibility Voltage Regulator Signal Voltage Too High Voltage Regulator Signal Voltage Too Low EEPROM Plausibility Checksum Error EEPROM Plausibility Code Word Incorrect Or Missing EEPROM Plausibility Communication Error EEPROM Plausibility Variation Number Error EEPROM Plausibility VIN Checksum Error EEPROM Plausibility VIN W
214. of vehicle 2 Attach one end of a hose to the draincock Put the other end into a dean container Open draincock and drain coolant from radiator This will empty the coolant reserve overflow tank The coolant does not have to be removed from the tank unless the system is being refilled with a fresh mixture Remove radia tor cap and continue draining cooling system COOLANT Continued STANDARD PROCEDURE COOLING SYSTEM FILLING Remove pressure vent cap and fill system using a 50 50 mix of Antifreeze Coolant 5 Year 100 000 Mile Formula and distilled water Continue filling system until full Be careful not to spill coolant on drive belts or the generator Fill coolant recovery pressure container to at least the MAX mark with 50 50 solution It may be neces sary to add coolant to the coolant recovery pressure container after three or four warm up cool down cycles to maintain coolant level between the MAX and MIN mark This will allow trapped air to be removed from the system STANDARD PROCEDURE REFILLING COOLING SYSTEM 1 Tighten the radiator draincock and the cylinder block drain plug s if removed CAUTION Failure to purge air from the cooling sys tem can result in an overheating condition and severe engine damage 2 Fill system using a 50 50 mixture of ethylene glycol antifreeze and low mineral content water until coolant remains in the bottom of the coolant reserve overflow Install radi
215. oling fan and fan drive viscous clutch assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH INSTALLATION 11 Connect negative battery cable OIL DESCRIPTION Refer to the appropriate owner manual for oil spec ifications KJ OIL FILTER ADAPTER DESCRIPTION An oil filter adapter is used on this vehicle to relo cate the oil filter for easier access when servicing Fig 59 80cb3a9a Fig 59 OIL FILTER ADAPTER WATER PUMP HOUSING STUDS WATER PUMP HOUSING RETAINING NUTS O RING O RING O RING OIL FILTER ADAPTER TO OIL COOLER RETAINING BOLT LOCK WASHER OIL FILTER ADAPTER TO ENGINE BLOCK RETAINING BOLT OIL COOLER ASSEMBLY 10 OIL COOLER TO ENGINE BLOCK RETAINING BOLT 11 OIL FILTER ADAPTER ASSEMBLY 12 ENGINE BLOCK ENGINE 9 45 OIL REMOVAL 1 Disconnect negative battery cable 2 Remove engine cover Refer to 9 ENGINE REMOVAL NOTE When insialling engine support fixture care must be taken not to damage the hood ajar switch mounted to the right inner fender 3 Install 8534 4 Raise vehicle on hoist 5 Remove both front wheel and tire assemblies 6 Remove front skid plate if equipped 7 Drain engine oil 8 Remove front axle assembly Refer to 3 DIF FERENTIAL REMOVAL 9 Loosen both engine mount through bolts 10 Lower vehicle 11 Raise engine using support fixture special tool 8534 unti
216. on temperature To reduce the emission of these oxides the cylinder tempera ture must be lowered The system allows a predeter mined amount of hot exhaust gas to recirculate and dilute the incoming charge air The diluted air mix ture reduces peak flame temperature during combus tion REMOVAL 1 Remove engine cover 2 Partially drain cooling system 3 Disconnect vacuum line at EGR valve Fig 1 4 Disconnect coolant hoses at EGR valve Fig 1 5 Remove the EGR pipe to exhaust manifold bolt retaining bolt 2 5L 6 Disconnect tube at rear of EGR valve cooler 2 8L Fig 1 7 Remove EGR valve cooler to exhaust manifold retaining bolt 2 8L Fig 1 8 Remove EGR valve to exhaust manifold retain ing bolt Fig 1 9 Remove EGR valve 2 5L and cooler assembly 2 8L from vehicle 10 Remove EGR valve to cooler retaining bolts 2 8L and separate EGR valve from cooler INSTALLATION 1 Connect EGR valve to cooler with new gasket 2 8L Torque bolts to 32 4N m 2 Install EGR valve cooler assembly on EGR valve mounting studs with new gasket Fig 1 3 Install EGR valve retaining nuts Fig 1 Torque nuts to 32 4N m 4 Install EGR pipe with new gasket to EGR valve bolts 2 5L Torque bolts to 32 4N m 5 Install EGR pipe or cooler to exhaust manifold retaining bolts Fig 1 Torque bolt to 24 5N m 6 Connect tube at rear of EGR cooler 2 8L 7 Connect EGR cooler coolant hoses 2 8
217. ondenser 11 Dragging Brakes 12 Non factory bug screen is being used reducing air flow 13 Thermostat partially or completely shut This is more prevalent on high mileage vehicles 14 Cylinder head gasket leaking 15 Heater core leaking 1 This may be a temporary condition and repair is not necessary Turn off the air conditioning and attempt to drive the vehicle without any of the previous conditions Observe the temperature gauge The gauge should return to the normal range If the gauge does not return to normal range determine the cause for the overheating and repair 2 Check gauge Refer to group 3 Check for coolant leaks and repair as necessary 4 Tighten cap 5 a Check condition of cap and cap seals b Check condition of coolant tank filler neck Make sure it does not leak pressure 6 Check antifreeze Adjust antifreeze to water ratio as required 7 Check for coolant flow in coolant tank with engine warm and thermostat open Coolant should be observed flowing through the tank If flow is not observed determine reason for lack of flow and repair as necessary 8 Clean debris from radiator or A C condenser 9 Have radiator re cored or replaced 10 Install proper A C condenser 11 Check and correct as necessary 12 Only a factory screen should be used 13 Check thermostat and replace if necessary 14 Check cylinder head gasket for leaks 15 Check heater core for l
218. or Circuit Overcurrent High Side Oylinder 1 Injector Circuit Overcurrent Low Side Oylinder 2 Injector Circuit Current Decrease Oylinder 2 Injector Circuit Load Drop Oylinder 2 Injector Circuit Overcurrent High Side Oylinder 2 Injector Circuit Overcurrent Low Side Oylinder 3 Injector Circuit Current Decrease Cylinder 3 Injector Circuit Load Drop Cylinder 3 Injector Circuit Overcurrent High Side Cylinder 3 Injector Circuit Overcurrent Low Side Cylinder 4 Injector Circuit Current Decrease Cylinder 4 Injector Circuit Load Drop Cylinder 4 Injector Circuit Overcurrent High Side Cylinder 4 Injector Circuit Overcurrent Low Side Boost Pressure Sensor Plausibility Boost Pressure Sensor Signal Voltage Too Low Boost Pressure Sensor Signal Voltage Too High Boost Pressure Sensor Signal Voltage Too High Or Low CKP Position Sensor Circuit Dynamic Plausibility CKP Position Sensor Circuit Overspeed Recognition CKP Position Sensor Circuit Static Plausibility CMP Position Sensor Circuit CMP CKP Sync Failure CMP Position Sensor Circuit Dynamic Plausibility CMP Position Sensor Circuit Fuel Shut Off Activated CMP Position Sensor Circuit Signal Frequency Too High CMP Position Sensor Circuit Static Plausibility Glow Plug Circuit A Open Circuit Glow Plug Circuit A Short Circuit EGR Solenoid Circuit Open Circuit EGR Solenoid Circuit Short Circuit Fan 1 Control Circuit Open Circuit Fan 1 Control Circuit Short Circuit P04
219. orresponding hole in the clutch assembly 2 5L Install the transmission assembly on the engine block mounted dowel pins 2 8L if possible If this proves to difficult removal of the transmission may be required 3 Connect oil pressure sensor located between the engine block and the turbocharger 4 Connect crankshaft position sensor located on the right rear of the engine 5 Install right side engine mount on the engine block 6 Disconnect assembly 7 Raise and support the vehicle lifting device from the engine 8 Install all transmission to engine retaining bolts 9 Install exhaust inlet pipe and retaining bolts 10 Install chassis ground wire above starter mounting location on the engine block 11 Install starter motor on the engine 12 Install oil filter and cooler assembly 13 Lower vehicle 14 Install oil cooler adapter 15 Install coolant elbow and retaining bolts and connect the hoses leading from it 16 Trace engine wiring and connect electrical connectors and tie straps one at a time until all wir ing is connected on engine assembly 17 Install low side refrigerant line 18 Install generator on the engine Refer to 8 ELECTRICAL CHARGING GENERATOR INSTAL LATION 19 Connect heater core inlet and outlet hoses at heater core 20 Connect four large electrical connectors near rear of the right front fenderwell 21 Install engine cover mounting bracket and retaini
220. po nents are installed in the same position as before dis assembly determined by the numbers stamped on the crown of individual pistons Engine cylinders are numbered starting from gear train end of the engine PISTON amp CONNECTING ROD Continued Face arrow on top of piston toward front of engine Therefore the numbers stamped on connect ing rod big end should face toward the injection pump side of engine To insert piston into cylinder use a ring compressor as shown in Fig 52 INSTALLATION 1 Before installing pistons and connecting rod assemblies into the bore be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap Fig 51 2 Before installing the ring compressor make sure the oil ring expander ends are butted together 3 Immerse the piston head and rings in clean engine oil slide the ring compressor over the piston and tighten Fig 52 Ensure position of rings does not change during this operation 4 Face arrow on piston towards front of engine NOTE Be careful not to nick crankshaft journals 5 Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore Insert rod and piston into cylinder bore and guide rod over the crankshaft journal 80 6 11 Fig 52 PISTON INSTALLATION USING VM 1065 1 PISTON 2 VM 1065 PISTON RING COMPRESSOR 3 ENGINE BLOCK 6 Tap the piston down in cylinder bore using a ha
221. port and tighten nut using special tool 6958 span ner wrench 5 Connect negative battery cable RADIATOR REMOVAL 1 Disconnect negative battery cable 2 Drain cooling system Refer to 7 COOLING ENGINE STANDARD PROCEDURE 3 Remove engine oil fill cap 4 Remove engine cover Refer to 9 ENGINE COVER REMOVAL 5 Remove air filter assembly from the engine bay 6 Recover and evacuate the refrigerant system Refer to 24 HEATING amp AIR CONDITIONING PLUMBING STANDARD PROCEDURE and Refer to 24 HEATING amp AIR CONDITIONING PLUMB ING STANDARD PROCEDURE 7 Disconnect high side refrigerant line from the upper radiator support bracket 8 Remove upper radiator support bracket retain ing bolts and remove the support bracket 9 Remove high side refrigerant line retaining nut and remove the line from the condenser assembly Position the line out of the way 10 Unbolt cooling fan from cooling fan support 11 Remove fan shroud retaining bolts and remove the fan and shroud as an assembly 12 Disconnect charge air cooler hoses from the charge air cooler 13 Disconnect engine coolant hoses from the radi ator 14 Disconnect coolant reservoir hose from the radiator 7 24 ENGINE RADIATOR Continued 15 Remove low side refrigerant line retaining nut and remove the line from the condenser assembly Position the line out of the way 16 Remove condenser assembly retaining bolts and
222. r as necessary 4 Check coolant level in the coolant tank Inspect system for leaks Repair leaks as necessary Refer to the Coolant section for WARNINGS and precautions before removing the pressure cap 5 Inspect heater and repair as necessary Refer to Heating and Air Conditioning for procedures 4 Coolant level low in cold ambient temperatures accompanied with poor heater performance 5 Improper operation of internal heater doors or heater controls 7 4 COOLING 2 5L 2 8L TURBO DIESEL COOLING 2 5L 2 8L TURBO DIESEL Continued CONDITION POSSIBLE CAUSES KJ CORRECTION TEMPERATURE GAUGE READS HIGH COOLANT MAY OR MAY NOT BE LOST OR LEAKING FROM COOLING SYSTEM 1 Trailer is being towed a steep hill is being climbed vehicle is operated in slow moving traffic or engine is being idled with very high ambient outside temperature and the air conditioning is on Higher altitudes could aggravate these conditions 2 Temperature gauge reading incorrectly 3 Coolant low in coolant tank and radiator 4 Pressure cap not installed tightly If cap is loose boiling point of coolant will be lowered 5 Poor seals at pressure vent cap 6 Freeze point of antifreeze not correct Mixture may be too rich 7 Coolant not flowing through system 8 Radiator or A C condenser fins are dirty or clogged 9 Radiator core is corroded or plugged 10 Aftermarket A C installed without proper A C c
223. r plunger by unscrewing it counterlockwise Fig 1 3 Pull primer up out of bore until it stops Fig 1 4 Pump primer plunger up and down until air bubbles cannot be seen in fuel filter cap at the bot tom of the fuel filter water separator Fig 1 80cef875 Fig 1 FUEL FILTER PRIMING PLUNGER 1 FUEL FILTER PRIMING PLUNGER 2 AIR BLEED 3 FUEL FILTER WATER SEPARATOR STANDARD PROCEDURES CLEANING FUEL SYSTEM COMPONENTS CAUTION Cleanliness cannot be overemphasized when handling or replacing diesel fuel system com ponents This especially includes the fuel injectors high pressure fuel lines fuel rail and fuel injection pump Very tight tolerances are used with these parts Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes This in turn could lead to possible engine misfire Always wash clean any fuel system compo nent thoroughly before disassembly and then air dry DO NOT wire brush injector nozzles when cleaning Cap or cover any open part after disas sembly Before assembly examine each part for dirt grease or other contaminants and clean if nec essary When installing new parts lubricate them with clean engine oil or clean diesel fuel only FUEL SYSTEM 14 3 FUEL SYSTEM 2 5L 2 8L TURBO DIESEL Continued SPECIFICATIONS TORQUE 2 5L 2 81 DIESEL TORQUE SPECIFICATIONS DESCRIPTION Crankshaft Position 0 8 Sensor Bolt Boost Pressur
224. recognizes as potentially damaging to the transmission The TCM also performs certain self diagnostic functions and provides comprehensive information sensor data DTC s etc which is helpful in proper diagnosis and repair This information can be viewed with the DRB scan tool KJ AUTOMATIC TRANSMISSION 545RFE 21 3 AUTOMATIC TRANSMISSION 545RFE Continued DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING AUTOMATIC TRANSMISSION CAUTION Before attempting any repair on a 545RFE automatic transmission check for Diagnos tic Trouble Codes with the DRB scan tool Transmission malfunctions may be caused by these general conditions e Poor engine performance e Improper adjustments e Hydraulic malfunctions e Mechanical malfunctions e Electronic malfunctions Diagnosis of these problems should always begin by checking the easily accessible variables fluid level and condition gearshift cable adjustment Then per form a road test to determine if the problem has been corrected or if more diagnosis is necessary If the problem persists after the preliminary tests and cor rections are completed hydraulic pressure checks should be performed DIAGNOSIS AND TESTING ROAD TESTING Before road testing be sure the fluid level and con trol cable adjustments have been checked and adjusted if necessary Verify that all diagnostic trou ble codes have been resolved Observe engine performance during the road test A poorly t
225. rimary stage of the pump works continuously the second stage is bypassed when demand is low The control system also moni tors input and output speed and if incipient clutch slip is observed the pressure control solenoid duty cycle is varied increasing pressure in proportion to demand A high travel torque converter damper assembly allows earlier torque converter dutch engagement to reduce slippage Needle type thrust bearings reduce internal friction The 545RFE is packaged in a one piece die cast aluminum case To reduce NVH the case has high lateral vertical and torsional stiffness It is also designed to maximize the benefit of the structural dust cover that connects the bottom of the bell housing to the engine bedplate enhancing over all power train stiffness Dual filters protect the pump and other components A pump return filter is added to the customary main sump filter Indepen dent lubrication and cooler circuits assure ample pressure for normal transmission operation even if the cooler is obstructed or the fluid cannot flow due to extremely low temperatures The hydraulic control system design without elec tronic assist provides the transmission with PARK REVERSE NEUTRAL SECOND and THIRD gears based solely on driver shift lever selection This design allows the vehide to be driven in limp in mode in the event of a electronic control system fail ure or a situation that the Transmission Control Module
226. riming plunger Refer to 14 FUEL SYSTEM STANDARD PROCEDURE 5 Connect negative battery cable FUEL DELIVERY 14 17 FUEL PRESSURE SOLENOID OPERATION The fuel pressure solenoid sets the correct pressure DESCRIPTION in the fuel rail as a function of engine loading and The fuel pressure solenoid is attached to the rear Maintains it at the proper level If the rail pressure of the injection pump Refer to 14 FUEL SYSTEM is excessive the solenoid opens and a portion of the WARNING Fig 21 fuel returns from the fuel rail to the fuel tank via a return line If the rail pressure is too low the sole noid closes and seals off the high pressure stage from the low pressure stage Refer to 14 FUEL SYSTEM WARNING 80c4bSed Fig 21 FUEL INJECTION PUMP 1 FUEL INJECTION PUMP 2 INJECTION PUMP PRESSURE SOLENOID 14 18 FUEL INJECTION FUEL ECTION TABLE OF CONTENTS page CRANKSHAFT POSITION SENSOR DESCRIPTION 18 OPERATION iere nc ate Rt e 18 REMOVAL 2 25228 5 HERES 18 INSTALLATION 18 ACCELERATOR PEDAL POSITION SENSOR DESCRIPTION 4555956 Rec ee Rs 19 REMOVAL bade 19 INSTALLATION 19 BOOST PRESSURE SENSOR DESCRIPTION 45855 e RR eis 20 OPERATION orig ea ee gdida RARE ES 20 DIAGNOSIS AND TESTING BOOST PRESSURE INTAKE AIR TEMPERATURE SENSOR reieun ea Eak 20 REMOVAL
227. rite Error SKIM System Invalid Key Code Received SKIM System Invalid Secret Key In EEPROM SKIM System Key Communication Timed Out SKIM System SKIM Error SKIM System Write Access To EEPROM Failure EEPROM Communication Error EEPROM Communication Not Verified EEPROM Quanity Stop EEPROM Recovery Occured EEPROM Redundant Overrun Monitoring Brake Switch Signal CKTS Plaus With Redundant Contact After Initialization Acc Pedal Position Sensor 1 CKT Plausibility Acc Pedal Position Sensor 1 CKT Plausibility With Brake Switch Acc Pedal Position Sensor 1 CKT Plausibility With Potentiometer Acc Pedal Position Sensor 1 CKT Signal Voltage Too High Acc Pedal Position Sensor 1 CKT Signal Voltage Too Low Acc Pedal Position Sensor 1 CKT Signal Voltage Too High or Low KJ EXHAUST GAS RECIRCULATION TABLE OF CONTENTS page EXHAUST GAS RECIRCULATION DESCRIPTION ize y Ee Sadie ews 7 OPERATION 7 VALVE DESGRIPTION 2283 44 den nde bd 8 OPERATION 241 4 4 4242 46 do are de 8 REMOVAL 8 INSTALLATION 8 EXHAUST GAS RECIRCULATION DESCRIPTION The EGR system reduces oxides of nitrogen NOx in the engine exhaust This is accomplished by allow ing a predetermined amount of hot exhaust gas to recirculate and dilute the incoming charge air A malfunctioning EGR system can cause engine stumble sags or
228. rive vis cous clutch four bolts 2 Lay fan on a flat surface with leading edge fac ing down With tip of blade touching flat surface replace fan if clearance between opposite blade and surface is greater than 2 0 mm 090 inch Rocking motion of opposite blades should not exceed 2 0 mm 090 inch Test all blades in this manner 3 Inspect fan assembly for cracks bends loose rivets or broken welds Replace fan if any damage is found INSTALLATION INSTALLATION COOLING FAN 1 Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH INSTALLATION INSTALLATION COOLING FAN SUPPORT 1 Install cooling fan support to engine block Fig Torque bolts to 47 1N m 2 Install fan drive viscous clutch and fan assem bly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH INSTALLATION 3 Connect negative battery cable KJ COOLANT SYSTEM HOSES REMOVAL REMOVAL UPPER RADIATOR HOSE 1 Drain cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 2 Disconnect upper radiator hose from thermo stat housing Fig 2 3 Disconnect upper radiator hose from radiator and remove from vehicle Fig 2 80cd9deb Fig 2 UPPER RADIATOR HOSE FAN SHROUD HOSE CLAMP UPPER RADIATOR HOSE THERMOSTAT HOUSING REMOVAL HEATER CORE HOSES 1 Drain cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 2 Remove engine cover from engine Refer to 9 ENGINE
229. rtial EMCC will usually occur at low speeds low load and light throttle situations FULL EMCC During Full EMCC operation the TCM increases the L R Solenoid duty cycle to full ON after Partial EMCC control brings the engine speed within the desired slip range of transmission input speed rela tive to engine rpm GRADUAL TO NO EMCC This operation is to soften the change from Full or Partial EMCC to No EMCC This is done at mid throttle by decreasing the L R Solenoid duty cycle TRANSMISSION SOLENOID TRS ASSEMBLY DESCRIPTION The transmission solenoid TRS assembly is inter nal to the transmission and mounted on the valve body assembly Fig 24 The assembly consists of six solenoids that control hydraulic pressure to the six friction elements transmission clutches and the torque converter dutch The pressure control sole noid is located on the side of the solenoid TRS assem bly The solenoid TRS assembly also contains five pressure switches that feed information to the TCM OPERATION SOLENOIDS Solenoids are used to control the L R 2C 4C OD and UD friction elements The reverse clutch is con KJ 80ceb3ca Fig 24 Transmission Solenoid TRS Assembly PRESSURE CONTROL SOLENOID TRANSMISSION RANGE SELECTOR PLATE 23 WAY CONNECTOR SOLENOID PACK TRANSMISSION RANGE SENSOR VALVE BODY trolled by line pressure and the position of the man ual valve in the valve body All
230. scribes your driving conditions Where time and mileage are listed follow the interval that occurs first CAUTION Failure to perform the required mainte nance items may result in damage to the vehicle At Each Stop for Fuel e Check the engine oil level about 5 minutes after a fully warmed engine is shut off Checking the oil level while the vehicle is on level ground will improve the accuracy of the oil level reading Add oil only when the level is at or below the ADD or MIN mark e Check the windshield washer solvent and add if required Once a Month e Check the tire pressure and look for unusual wear or damage e Inspect the battery and clean and tighten the terminals as required e Check the fluid levels of coolant reservoir brake master cylinder power steering and transmission and add as needed e Check all lights and all other electrical items for correct operation At Each Oil Change e Change the engine oil filter Inspect the exhaust system Inspect the brake hoses e Check the manual transmission fluid level if equipped e Check the coolant level hoses and clamps e Inspect engine accessory drive belts Replace as necessary e Inspect for the presence of water in the fuel fil ter water separator unit e Rotate the tires Schedule B Follow schedule B if you usually operate your vehicle under one or more of the following conditions e Extensive engine idling e Driving in d
231. sket mating surfaces 2 Position correct head gasket on engine block 3 Place cylinder head on engine block 9 20 ENGINE CYLINDER HEAD Continued CAUTION New cylinder head bolts must be used 4 Tighten cylinder head bolts following procedure below Cylinder Head Bolt Torquing Procedure 1 Lubricate cylinder head bolts with engine oil 2 Torque bolts to 30N m in numerical starting with bolt 1 Fig 10 3 Tighten all bolts an additional 50 starting with bolt 44 then 5 6 7 8 9 10 1 2 3 11 12 13 14 15 16 17 18 Fig 10 4 Finally tighten all bolts an additional 75 in numerical order starting with bolt 1 Fig 10 80c5ddfe Fig 10 CYLINDER HEAD TORQUE SEQUENCE 5 Slide exhaust manifold and turbocharger on exhaust manifold studs Fig 11 6 Install exhaust manifold retaining nuts Torque nuts to 32 4N m 7 Install exhaust manifold heat shield Torque bolts to 27 5N m 8 Install turbocharger outlet to charge air cooler pipe 9 Install upper radiator hose 10 Connect glow plug and coolant temperature sensor electrical connectors 11 Install new cylinder head cover intake mani fold gasket 12 Install rocker arm and lifter assemblies Be sure to put rocker arm and lifter assemblies in same location as removed 13 Install cylinder head cover intake manifol d Refer to 9 ENGINE CYLINDER HEAD CYLIN DER HEAD COVER S INSTALLATION KJ 8105d55a Fig 11 THERMOSTA
232. sor receives a 5 volts reference from the ECM Sensor ground is also provides by the ECM The ECM uses boost pressure combined with intake air temerature to determine the volume of air entering the engine DIAGNOSIS AND TESTING BOOST PRESSURE INTAKE AIR TEMPERATURE SENSOR f the boost pressure sensor fails the ECM records a DTC into memory and continues to operate the engine in one of the three limp in modes When the ECM is operating in this mode a loss of power will be present as if the turbocharger was not operating The best method for diagnosing faults with the boost pressure sensor is with the DRB 1119 scan tool Refer to the Diesel Powertrain Diagnostic Manual for more information BOOST PRESSURE SENSOR Continued Refer to On Board Diagnostics in Emissions Con trol System for a list of Diagnostic Trouble Codes DTC s for certain fuel system components REMOVAL 1 Disconnect negative battery cable 2 Remove engine cover and bracket assembly Refer to 9 ENGINE COVER REMOVAL 3 Disconnect sensor electrical connector Fig 8 4 Remove retaining bolts and remove sensor from cylinder head cover intake manifold Fig 8 80cf1e6f Fig 8 SENSOR LOCATIONS 1 BOOST PRESSURE INTAKE AIR TEMPERATURE SENSOR 2 FUEL PRESSURE SENSOR INSTALLATION 1 Install sensor and retaining bolts into cylinder head cover intake manifold Fig 8 Torque to 5 4 N m 2 Connect sensor electrical connector Fig
233. ss through the EGR solenoid and on to the EGR valve with a connecting hose Exhaust gas recirculation will begin in this order when e The ECM determines that EGR system opera tion is necessary e The engine is running to operate the vacuum pump e A variable ground signal is supplied to the EGR solenoid e Variable vacuum passes through the EGR sole noid to the EGR valve e The inlet seat poppet valve at the bottom of the EGR valve opens to dilute and recirculate exhaust gas back into the intake manifold e The EGR Cooler 2 8L further cools the hot exhaust gasses before recirculation The EGR system will be shut down by the ECM after 60 seconds of continuous engine idling to improve idle quality 25 8 EXHAUST GAS RECIRCULATION VALVE DESCRIPTION The EGR system consists of Fig 1 e EGR valve e Vacuum hoses e EGR cooler 2 8L e EGR solenoid 80cb44ee Fig 1 EGR VALVE COOLER AND COMPONENTS COOLANT HOSE HOSE RETAINER RETAINING BOLT EGR VALVE RETAINING NUTS EGR VALVE EGR VALVE GASKET HOSE CLAMP COOLANT HOSE HOSE CLAMP D ren COOLER TO EXHAUST MANIFOLD RETAINING BOLT 11 EGR COOLER 2 8L 12 EGR COOLER TO EGR VALVE RETAINING BOLTS 2 8L 13 EGR COOLER TO EGR VALVE GASKET 2 8L 14 HOSE CLAMP OPERATION The EGR system reduces oxides of nitrogen NOx in engine exhaust Formation of NOx increases pro portionally with combusti
234. stall retaining nuts and torque to 36N m EXHAUST SYSTEM AND TURBOCHARGER 11 9 80cb4480 Fig 13 EXHAUST MANIFOLD AND COMPONENTS THERMOSTAT HOUSING GASKET THERMOSTAT HOUSING TURBOCHARGER OIL SUPPLY LINE BANJO BOLT THERMOSTAT HOUSING RETAINING BOLTS BRASS WASHER EXHAUST MANIFOLD GASKET EXHAUST MANIFOLD EXHAUST MANIFOLD HEAT SHIELD EXHAUST MANIFOLD HEAT SHIELD RETAINING BOLTS OIL RETURN HOSE HOSE CLAMPS EXHAUST MANIFOLD RETAINING NUTS TURBOCHARGER DOWN PIPE STUDS 14 TURBOCHARGER DOWN PIPE GASKET 15 TURBOCHARGER DOWN PIPE 16 TURBOCHARGER DOWN PIPE RETAINING NUT mk wr 3 Install thermostat housing Refer to 7 COOL ING ENGINE ENGINE COOLANT THERMOSTAT INSTALLATION 4 Install viscous heater Refer to 24 HEATING amp AIR CONDITIONING PLUMBING ELECTRIC COOLANT PUMP INSTALLATION 5 Install accessory drive belt Refer to 7 COOL ING ACCESSORY DRIVE DRIVE BELTS INSTAL LATION 6 Raise vehicle on hoist 11 10 TURBOCHARGER Continued 80cb4415 Fig 14 EXHAUST MANIFOLD AND TURBOCHARGER ASSEMBLY 1 EGR VALVE MOUNTING STUDS 2 EXHAUST MANIFOLD 2 TO EXHAUST MANFOLD MOUNTING 4 TURBOCHARGER ASSEMBLY TURBOCHARGER OIL RETURN FITTING ATTACHING BOLT TURBOCHARGER OIL RETURN FITTING OIL RETURN FITTING GASKET RETAINING NUT TURBOCHARGER TO EXHAUST MANIFOLD GASKET EXHAUST SYST
235. switches The other inputs might have to be sensed by the ECM when it senses a high or low input voltage from the control system device in question 25 2 EMISSIONS CONTROL 2 5L 2 8L TURBO DIESEL KJ EMISSIONS CONTROL 2 5L 2 8L TURBO DIESEL Continued SPECIFICATIONS TORQUE 2 5L 2 81 DIESEL TORQUE SPECIFICATIONS DESCRIPTION nm Fis E 344 0 0 EGR Pipe to Exhaust 24 5 18 Manifold Bolt EGR Cooler to EGR Valve 32 4 24 Bolts EGR Cooler to Exhaust 24 5 18 Manifold Bolt KJ ON BOARD DIAGNOSTICS 25 3 ON BOARD DIAGNOSTICS TABLE OF CONTENTS page ON BOARD DIAGNOSTICS DESCRIPTION DIAGNOSTIC TROUBLE CODES aseman mpa 3 ON BOARD DIAGNOSTICS DESCRIPTION DIAGNOSTIC TROUBLE CODES On the following pages a list of DTC s is provided for the 2 5L 2 8L diesel engine A DTC indicates that the ECM has recognized an abnormal signal in a cir cuit or the system A DTC may indicate the result of a failure but most likely will not identify the failed component directly Refer to the appropriate diagnos tic manual for more information on diagnosis of trou ble codes ENGINE CONTROL MODULE ECM CODES Generic Scan Tool Code ACCESSING DIAGNOSTIC TROUBLE CODES A stored DTC can be displayed through the use of the DRB 1119 scan tool The DRB 1119 connects to the data link connector The data link connector is located under the instrument panel near bo
236. system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 4 Remove radiator core support 5 Remove cooling fan and fan drive viscous clutch assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 6 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 7 Remove accessory drive belt tensioner and both idler pulleys Idler pulley bolts are L H thread Refer to 7 COOLING ACCESSORY DRIVE BELT TENSIONERS REMOVAL 8 Remove power steering pump pulley 9 Remove front engine lift bracket 10 Remove cooling fan support Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL 11 Remove generator and support bracketing Re fer to 8 ELECTRICAL CHARGING GENERATOR REMOVAL 12 Remove viscous heater 13 Remove vibration damper 14 Remove throttle cable assembly and set aside 15 Disconnect main engine wiring harness con nectors from right inner wheel housing 16 Disconnect main engine wiring harness ancil lary components and set harness aside 17 Remove air cleaner housing 18 Disconnect EGR cooler assembly water inlet pipe 19 Remove EGR cooler from exhaust manifold 2 8L Disconnect coolant pipe 2 5L Refer to 25 EMISSIONS CONTROL EXHAUST GAS RECIRCU LATION VALVE COOLER REMOVAL 20 Remove exhaust manifold heat shield Fig 7 21 Remove turbocharger heat shield retaining bolt and position shield aside Fig 9 22
237. t rotates the lobes of the camshafts apply downward pressure on the rocker arms This pressure is then transmitted to the valves which causes the valves to open KJ B0d368c5 Fig 20 CYLINDER HEAD ASSEMBLY CYLINDER HEAD BOLT GLOW PLUG COOLANT TEMPERATURE SENSOR CYLINDER HEAD ALIGNMENT DOWEL GLOW PLUG HARNESS CYLINDER LINER CYLINDER BLOCK CYLINDER HEAD GASKET CYLINDER HEAD 0 ROCKER ARM ASSEMBLIES 1 2 3 4 5 6 7 8 9 1 REMOVAL 1 Disconnect negative battery cable 2 Drain cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 3 Remove cooling fan and fan drive viscous clutch assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 4 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 5 Remove cooling fan support Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL 6 Remove vibration damper 7 Remove outer timing belt cover Refer to 9 TIMING TIMING BELT CHAIN COVER S REMOVAL 8 Remove timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL ROCKER ARMS Continued 9 Remove inner timing belt cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 10 Remove cylinder head cover intake manifold Refer to 9 ENGINE CYLINDER HEAD CYLIN DER HEAD COVER S REMOVAL 1
238. t tensioner Fig 78 80ae1cd6 Fig 78 TIMING BELT AND SPROCKETS CAMSHAFT SPROCKETS INJECTION PUMP SPROCKET INJECTION PUMP SPROCKET RETAINING NUT TIMING BELT TIMING BELT TENSIONER RETAINING BOLT TIMING BELT TENSIONER TENSIONER ALIGNMENT PIN IDLER PULLEY CAMSHAFT SPROCKET RETAINING BOLT 9 58 ENGINE KJ TIMING BELT CHAIN TENSIONER amp PULLEY Continued INSTALLATION NOTE DO NOT remove the timing belt from the package uniil it s ready to be installed DO NOT expose timing belt to oil grease or water contami nation DO NOT crimp belt at a sharp angle DO NOT clean belt pulleys or tensioner with solvent Check that pulleys and bearings are not seized or damage before installing belt 1 Install timing belt tensioner and retaining bolt 2 Adjust timing belt tensioner Refer to 9 ENGINE VALVE TIMING TMNG BELT CHAIN TENSIONER amp PULLEY ADJ USTMENTS 3 Install timing belt outer cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 4 Install vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER INSTAL LATION 5 Install cooling fan support Refer to 7 COOL ING ENGINE RADIATOR FAN INSTALLATION 6 Install accessory drive belt Refer to 7 COOL ING ACCESSORY DRIVE DRIVE BELTS INSTAL LATION 7 Install cooling fan and fan drive viscous dutch assembly Refer to 7 COOLING ENGINE FAN DR
239. tall accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 13 Install cooling fan and fan drive viscous clutch assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH INSTALLATION 14 Refill cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 15 Connect negative battery cable 9 24 ENGINE CYLINDER HEAD COVER DESCRIPTION The cylinder head cover is made of cast aluminum and is also the intake manifold on this engine Fig 16 80fec008 Fig 16 CYLINDER HEAD COVER INTAKE MANIFOLD REMOVAL CAUTION Before removing the cylinder head cover intake manifold the engine must put at 90 after TDC Failure to do so could result in valve and or piston damage during reassembly Refer to 9 ENGINE VALVE TIMING STANDARD PROCEDURE 1 Disconnect negative battery cable 2 Remove engine cover and bracket Refer to 9 ENGINE REMOVAL 3 Drain cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 4 Remove cooling fan and fan drive viscous drive assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 5 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 6 Remove cooling fan support Refer to 7 COOLING ENGINE RADIATOR FAN REMOVAL 7 Remove generator Refer to 8 ELECTRICAL CHARGING GENERATOR REMOVAL KJ CAUTION Before removing the cylinder head co
240. tates at engine speed The converter turbine driven member which reacts from fluid pressure generated by the impeller rotates and turns the transmission input shaft TURBINE As the fluid that was put into motion by the impel ler blades strikes the blades of the turbine some of the energy and rotational force is transferred into the turbine and the input shaft This causes both of them turbine and input shaft to rotate in a clockwise direction following the impeller As the fluid is leav ing the trailing edges of the turbine s blades it con tinues in a hindering direction back toward the impeller If the fluid is not redirected before it strikes the impeller it will strike the impeller in such a direction that it would tend to slow it down STATOR Torque multiplication is achieved by locking the stator s over running clutch to its shaft Fig 23 Under stall conditions the turbine is stationary the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counter clockwise direction When this happens the over run ning clutch of the stator locks and holds the stator AUTOMATIC TRANSMISSION 545RFE 21 41 TORQUE CONVERTER Continued
241. th two nuts on top and a slide bracket on the bot tom OPERATION The pressure chamber keeps the coolant free of trapped air provides a volume for expansion and con traction and provides a convenient and safe method for checking and adjusting coolant level at atmo spheric pressure It also provides some reserve cool ant to cover minor leaks evaporation or boiling losses The overflow chamber allows coolant recovery in case of an overheat COOLING FAN REMOVAL REMOVAL COOLING FAN 1 Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL REMOVAL COOLING FAN SUPPORT 1 Disconnect negative battery cable 2 Remove fan drive viscous clutch and fan assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH REMOVAL 3 Remove cooling fan support from engine block Fig 1 CLEANING Clean the fan blades using a mild soap and water Do not use an abrasive to clean the blades INSPECTION WARNING DO NOT ATTEMPT TO BEND OR STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN SPECIFICATIONS CAUTION If fan blade assembly 1 replaced because of mechanical damage water pump and fan drive viscous clutch should also be inspected These components could have been damaged due to excessive vibration 7 18 ENGINE COOLING FAN Continued 80cb41ec Fig 1 COOLING FAN SUPPORT IDLER PULLEY COOLING FAN SUPPORT RETAINING BOLTS ENGINE LIFT HOOK RON 1 Remove fan blade assembly from fan d
242. the engine is equipped with air conditioning the ECM A C function must be enabled Enable the ECM function as follows e Using the DRB 1119 select ENGINE MISCEL LANEOUS then ENABLE DISABLE A C e Push 1 to enable A C DRB 1119 screen should display A C Activated PROGRAMMING THE PCM JTEC The SKIS Secret Key is an ID code that is unique to each SKIM This code is programmed and stored in the SKIM PCM and transponder chip ignition keys When replacing the PCM it is necessary to program the secret key into the new PCM using the DRB 1119 Perform the following steps to program the secret key into the PCM 1 Turn the ignition switch on transmission in park neutral 2 Use the DRB 1119 and select THEFT ALARM SKIM then MISCELLANEOUS 3 Select PCM REPLACED GAS ENGINE 4 Enter secured access mode by entering the vehide four digit PIN 5 Select ENTER to update PCM VIN NOTE If three attempts are made to enter secure access mode using an incorrect PIN secured access mode will be locked out for one hour To exit this lockout mode turn the ignition to the RUN position for one hour then enter the correct PIN Ensure all accessories are turned off Also monitor ELECTRONIC CONTROL MODULES 8 3 the battery state and connect a battery charger if necessary 6 Press ENTER to transfer the secret key the SKIM will send the secret key to the PCM 7 Press Page Back to get to the Select System menu and select
243. the fuel gauge sending unit and the ECM are hard wired not multi plexed After the voltage signal is sent from the resistor track and back to the ECM the ECM will interpret the resistance voltage data and send a message across the multi plex bus circuits to the instrument panel cluster Here it is translated into the appropriate fuel gauge level reading Refer to Instrument Panel for additional information DIAGNOSIS AND TESTING FUEL LEVEL SENDING UNIT The fuel level sending unit contains a variable resistor track As the float moves up or down elec trical resistance will change Refer to Instrument Panel and Gauges for Fuel Gauge testing To test the gauge sending unit only it must be removed from vehicle The unit is a separate part of the lower fuel tank module section Refer to Fuel Tank Module Removal l nstallation for procedures remove only the upper section of the fuel pump module Measure the resistance across the sending unit terminals With float in up position resistance should be 20 ohms 47 596 With float in down position resistance should be 270 ohms 47 5 FUEL DELIVERY 14 15 REM OVAL The fuel level sending unit fuel level sensor and float assembly is located on the side of the lower sec tion of the fuel tank module The lower section of the fuel tank module is located within the fuel tank 1 Remove lower section of fuel tank module from fuel tank Refer to 14 FUEL SYSTEM FUEL DELIVERY FUEL
244. the solenoids are contained within the Solenoid and Pressure Switch Assembly The solenoid and pressure switch assembly contains one additional solenoid Multi Select MS which serves primarily to provide 2nd and 3rd gear limp in operation The solenoids receive electrical power from the Transmission Control Relay through a single wire The TCM energizes or operates the solenoids individ ually by grounding the return wire of the solenoid as necessary When a solenoid is energized the solenoid valve shifts and a fluid passage is opened or closed vented or applied depending on its default operat ing state The result is an apply or release of fric tional element The MS and UD solenoids are normally applied to allow transmission limp in in the event of an electri cal failure The continuity of the solenoids and circuits are periodically tested Each solenoid is turned on or off depending on its current state An inductive spike should be detected by the TCM during this test If no spike is detected the circuit is tested again to verify the failure In addition to the periodic testing the solenoid circuits are tested if a speed ratio or pres sure switch error occurs PRESSURE SWITCHES The TCM relies on five pressure switches to moni tor fluid pressure in the L R 2C 4 UD and OD KJ AUTOMATIC TRANSMISSION 545RFE 21 43 TRANSMISSION SOLENOID TRS ASSEMBLY Continued hydraulic circuits The primary purpose of these
245. tilled water Therefore these batteries have non removable battery vent caps Water cannot be added to this battery The acid inside an spiral plate battery is bound within the vitreous separators ending the threat of acid leaks This feature allows the battery to be installed in any position anywhere in the vehicle Spiral plate technology is the process by which the plates holding the active material in the battery are wound tightly in coils instead of hanging flat like conventional batteries This design has a lower inter nal resistance and also increases the active material surface area WARNING NEVER EXCEED 14 4 VOLTS WHEN CHARGING A SPIRAL PLATE BATTERY PERSONAL INJURY AND OR BATTERY DAMAGE MAY RESULT STANDARD PROCEDURE USING MICRO 420 BATTERY TESTER 4 Due to the maintanance free design distilled water cannot be added to this battery Therefore if more than 14 4 volts are used during the spiral plate bat tery charging process water vapor can be exhausted through the pressure sensitive battery vents and lost for good This can permanently damage the spiral plate battery Never exceed 14 4 volts when charging a spiral plate battery Personal injury and or battery damage may result Batteries are used to store electrical energy poten tial in a chemical form When an electrical load is applied to the battery terminals an electrochemical reaction occurs within the battery This reaction causes the batt
246. tinued 3 Install oil pump retaining bolts Torque bolts to 10 8N m 4 Install crankshaft sprocket Torque bolts to 10 8N m 5 Install ENGINE ENGINE INSTALLATION 6 Install timing belt inner cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 7 Install timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION 8 Install timing belt outer cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 9 Install vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER INSTAL Refer to 9 COVER front engine cover BLOCK ENGINE LATION 10 Install cooling fan support Refer to 7 COOLING ENGINE RADIATOR FAN INSTALLA TION 11 Install accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 12 Install cooling fan and fan drive viscous clutch assembly Refer to 7 COOLING ENGINE FAN DRIVE VISCOUS CLUTCH INSTALLATION 13 Connect negative battery cable OIL J DESCRIPTION There are four oil jets installed in the engine block These oil jets are used to cool and lubricate the pis ton assemblies Fig 66 80c6cbd5 Fig 66 OIL JET ASSEMBLY 1 RETAINING BOLT 2 OIL JET 3 O RING ENGINE 9 49 REMOVAL CAUTION Use caution when removing and install ing oil jets Damage to oil jet nozzle could cause severe engine damage
247. ttom of the steering column ERASING TROUBLE CODES After the problem has been repaired use the DRB 1119 scan tool to erase a DTC DRB Ill Scan Tool Display P0070 Ambient Air Temperature Circuit Signal Voltage Too High Ambient Air Temperature Circuit Signal Voltage Too Low P0100 Mass Air Flow Sensor Plausibility Mass Air Flow Sensor Plausibility Positive Area Mass Air Flow Sensor Signal Voltage Too High Mass Air Flow Sensor Signal Voltage Too Low Mass Air Flow Sensor Supply Voltage Too High Or Low Barometric Pressure Circuit Signal Voltage To High Barometric Pressure Circuit Signal Voltage To Low Intake Air Temperature Sensor Circuit Signal Too High Intake Air Temperature Sensor Circuit Signal Too Low Engine Coolant Temperature Sensor Circuit Engine Is Cold Too Long Engine Coolant Temperature Sensor Circuit Voltage To Low Engine Coolant Temperature Sensor Circuit Voltage To High Fuel Pressure Sensor Circuit MALF Signal Voltage Too High Fuel Pressure Sensor Circuit MALF Signal Voltage Too Low 25 4 ON BOARD 5 5 KJ ON BOARD DIAGNOSTICS Continued Generic Scan Tool Code DRB Scan Tool Display P0195 Oil Temperature Sensor Circuit MALF Signal Voltage Too High Oil Temperature Sensor Circuit MALF Signal Voltage Too Low P0201 Oylinder 1 Injector Circuit Current Decrease Cylinder 1 Injector Circuit Load Drop Oylinder 1 Inject
248. ual valve as the name implies is manually oper ated by the driver with a lever located on the top of the valve body The valve is connected mechanically by a cable to the gearshift mechanism The valve is held in each of its positions by a roller detent spring Fig 29 that engages the roostercomb of the TRS selector plate LOW REVERSE SWITCH VALVE The low reverse switch valve allows the low reverse dutch to be operated by either the LR CC solenoid or the MS solenoid AUTOMATIC TRANSMISSION 545RFE 21 45 80 072f3 Fig 29 TRS Selector Plate and Detent Spring 1 TRS SELECTOR PLATE 2 DETENT SPRING 3 CLUTCH PASSAGE SEALS EMISSIONS CONTROL 2 5L 2 8L TURBO DIESEL EMISSIONS CONTROL 2 5L 2 8L TURBO DIESEL TABLE OF CONTENTS page EMISSIONS CONTROL 2 5L 2 8L TURBO DIESEL DESCRIPTION EMISSIONS CONTROL 2 5L 2 8L TURBO DIESEL DESCRIPTION The 2 5L 2 8L diesel Engine Control Module ECM controls many different circuits in the fuel injection pump and engine systems If the ECM senses a prob lem with a monitored circuit that indicates an actual problem a Diagnostic Trouble Code DTC will be stored in the ECM s memory and eventually may illuminate the MIL Malfunction Indicator Lamp constantly while the key is on If the problem is repaired or is intermittent the ECM will erase the DTC after 40 warm up cydes without the fault detected A warm up cycle consists of starting the vehide whe
249. under specific conditions that cause them NOTE Electromagnetic radio interference can cause an intermittent system malfunction This interference can interrupt com munication between the ignition key transponder and the SKIM The following checks may assist you in identifying a possible intermittent problem e Visually inspect the related wire harness connec tors Look for broken bent pushed out loose fitting or corroded terminals e Visually inspect the related wire harness Look for chafed pierced or partially broken wire e Refer to hotlines or technical service bulletins that may apply Refer to the appropriate Diesel Powertrain Diag nostic Manual for more information ECM DIAGNOSTIC TROUBLE CODES IMPORTANT NOTE Before replacing the ECM for a failed driver control circuit or ground circuit be sure to check the related component circuit integrity for failures not detected due to a double fault in the circuit Most ECM driver control circuit failures are caused by internal failures to components i e relays and solenoids and shorted circuits i e sensor pull ups drivers and ground circuits These faults are difficult to detect when a double fault has occurred and only one DTC has set If the DRBIII9 displays faults for multiple components 1 55 ECT Batt Temp etc identify and check the shared circuits for possible problems before continuing 1 6 sensor grounds or 5 volt supply circuits Refer to the appro
250. uned engine will not allow accurate analy sis of transmission operation Operate the transmission in all gear ranges Check for shift variations and engine flare which indicates slippage Note if shifts are harsh spongy delayed early or if part throttle downshifts are sensitive Slippage indicated by engine flare usually means clutch overrunning clutch or line presure problems A slipping clutch can often be determined by com paring which internal units are applied in the vari ous gear ranges The Clutch Application chart provides a basis for analyzing road test results CLUTCH APPLICATION CHART SLP UD OD R 2 4 L R OVERRUNNING P PARK ON R REVERSE ON ON N NEUTRAL ON D OVERDRIVE 4 FIRST ON ON ON SECOND ON ON SECOND PRIME ON ON THIRD ON ON FOURTH ON ON FIFTH ON ON LIMP IN ON ON 2 FIRST ON ON ON SECOND ON ON LIMP IN ON ON 1 LOW ON ON ON L R clutch is on only with the output shaft speed below 150 rpm 21 4 AUTOMATIC TRANSMISSION 545RFE KJ AUTOMATIC TRANSMISSION 545RFE Continued DIAGNOSIS AND TESTING HYDRAULIC PRESSURE TEST An accurate tachometer and pressure test gauges are required Test Gauge C 3293 SP has a 300 psi range and is used at all locations where pressures exceed 100 psi Pressure Test Port Locations Only two pressure ports are supplied on the trans mission case The torque converter clutch apply and release ports are located on the right side of the transmission case Fig 2
251. ust be replaced NOTE Completely discharged batteries may take several hours to accept a charge Refer to Standard Procedures for the proper battery charging proce dures KJ STANDARD PROCEDURE STANDARD PROCEDURE SPIRAL PLATE BATTERY CHARGING Vehicles equipped with a diesel engine utilize a unique spiral plate battery This battery has a maxi mum charging voltage that must not be exceeded in order to restore the battery to its full potential fail ure to use the following spiral plate battery charging procedure could result in damage to the battery or personal injury Battery charging is the means by which the bat tery can be restored to its full voltage potential A battery is fully charged when e Micro 420 battery tester indicates battery is OK e Open circuit voltage of the battery is 12 65 volts or above e Battery passes Load Test multiple times WARNING IF THE BATTERY SHOWS SIGNS OF FREEZING LEAKING LOOSE POSTS OR LOW ELECTROLYTE LEVEL DO NOT TEST ASSIST BOOST OR CHARGE THE BATTERY MAY ARC INTERNALLY AND EXPLODE PERSONAL INJURY AND OR VEHICLE DAMAGE MAY RESULT CAUTION Always disconnect and isolate the bat tery negative cable before charging battery Charge the battery directly at the battery terminals Do not exceed 14 4 volts while charging a battery CAUTION The battery should not be hot to the touch If the battery feels hot to the touch turn off the charger and let the battery cool before
252. usty conditions e More than 50 of your driving is at sustained high speeds during hot weather above 32 C 90 F e Trailer towing e Taxi police or delivery service commercial ser vice 0 2 MAINTENANCE 5 KJ MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U S CANADA and MEXICO Continued T9900 km 20 000 m 30 000 20 000 m T s0 000 Change te engine engine oe X X x ern Replace engine accessory drive belt accessory drive belt Inspect the engine air filter element Replace as necessary Replace the engine air filter element the Replace the engine air filter element air filter element Replace the engine timing belt the engine Replace the engine timing belt belt Inspect idler pulleys and timing belt tensionert fuel filter water separator unit inspect the Brake Tings E EE Drain and refill the front and rear axle fluid Drain and refill automatic transmission fluid and replace transmission main sump filter Klometers 60 000 70 000 km 80 000 90 000 km 100 000 km Replace engine accessory drive belt accessory drive belt Inspect the engine air filter element Replace as necessary Replace the eng
253. ve snap ring from the input clutch retainer Fig 10 2 Remove the reverse reaction plate from the input clutch retainer 3 Remove the reverse hub and reverse dutch pack from the input clutch retainer 4 Remove the number 4 bearing from the over drive hub 5 Remove the overdrive hub from the input clutch retainer Fig 10 M gi AUTOMATIC TRANSMISSION 545RFE 21 33 6 Remove the number 3 bearing from the under drive hub 7 Remove the OD reverse reaction plate snap ring from the input clutch retainer 8 Remove the underdrive hub overdrive clutch and overdrive reaction plate from the input clutch retainer Fig 10 NOTE The overdrive friction discs and steel discs are thicker than the matching components in the underdrive and reverse clutches 808a2e68 Fig 10 Input Clutch Assembly Part 2 BEARING NUMBER 3 OD HUB SHAFT SNAP RING WAVE REV OD REACTION PLATE BEARING NUMBER 4 SNAP RING FLAT REVERSE HUB SHAFT REVERSE CLUTCH REVERSE REACTION PLATE 10 SNAP RING SELECT 11 PLATE 12 DISC 13 OD CLUTCH 14 SNAP RING TAPERED 15 UD OD REACTION PLATE 16 SNAP RING FLAT 17 UD HUB SHAFT 18 BEARING NUMBER 2 21 34 AUTOMATIC TRANSMISSION 545RFE INPUT CLUTCH ASSEMBLY Continued 9 Remove the number 2 bearing from the input clutch hub 10 Remove the overdrive clutch wave s
254. ve belt the belt MUST be routed correctly If not the engine may overheat due to the water pump rotating in the wrong direction 7 14 ACCESSORY DRIVE DRIVE BELT Continued 2 Install new belt Route the belt around all pul leys except the idler pulley Fig 6 Rotate the ten sioner arm until it contacts its stop position Route the belt around the idler and slowly let the tensioner rotate into the belt Make sure the belt is seated onto all pulleys Fig 6 80cdd35c Fig 6 ACCESSORY BELT ROUTING IDLER PULLEY GENERATOR IDLER PULLEY A C COMPRESSOR COOLING FAN SUPPORT VIBRATION DAMPER BELT TENSIONER POWER STEERING PUMP ACCESSORY DRIVE BELT 0 VISCOUS HEATER IDLER PULLEYS REMOVAL CAUTION The retaining bolts on the idler pulleys are left hand thread 1 Disconnect negative battery cable 2 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 3 Remove idler pulley retaining bolts and pulleys Fig 7 Fig 8 80cb41ec Fig 7 COOLING FAN SUPPORT IDLER PULLEY COOLING FAN SUPPORT RETAINING BOLTS ENGINE LIFT HOOK Kj 7 15 IDLER PULLEYS Continued INSTALLATION 1 Install idler pulleys and retaining bolts Fig 7 Fig 8 Torque bolts to 53N m 2 Install accessory drive belt Refer to 7 COOL ING ACCE
255. ver intake manifold or timing belt the engine must put at 90 after TDC Failure to do so could result in valve and or piston damage during reassembly Refer to 9 ENGINE VALVE TIMING STANDARD PROCEDURE 8 Rotate engine until 90 after TDC is reached Install both camshaft locking pins and the crankshaft locking pin Refer to 9 ENGINE VALVE TIMING STANDARD PROCEDURE 9 Remove outer timing belt cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 10 Remove timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL 11 Remove inner timing belt cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 12 Disconnect camshaft position sensor boost pressure intake air temperature sensor EGR sole noid and fuel pressure sensor electrical connectors 13 Disconnect vacuum lines at EGR solenoid 14 Position electrical harness out of way 15 Remove fuel injectors Refer to 14 FUEL SYSTEM FUEL INJECTION FUEL INJECTOR REMOVAL 16 Remove fuel rail Refer to 14 FUEL SYS TEM FUEL DELIVERY FUEL RAIL REMOVAL 17 Remove oil dipstick tube retaining bolt at intake manifold inlet 18 Disconnect oil separator outlet hose at separa tor 19 Remove turbo inlet tube retaining bolt at intake manifold 20 Disconnect EGR tube at intake manifold inlet tube 21 Remove cylinder head cover intake manifold retaining bolts F
256. way cruising range An additional overdrive ratio 0 67 1 is also provided for greater fuel economy and less NVH at highway speeds The hydraulic portion of the transmission consists of the transmission fluid fluid passages hydraulic valves and various line pressure control components The primary mechanical components of the trans mission consist of the following e Three multiple disc input clutches Three multiple disc holding clutches Five hydraulic accumulators Three planetary gear sets Dual Stage Hydraulic oil pump Valve body Solenoid pack 21 2 AUTOMATIC TRANSMISSION 545RFE KJ AUTOMATIC TRANSMISSION 545RFE Continued The TCM is the heart or brain of the electronic control system and relies on information from vari ous direct and indirect inputs sensors switches etc to determine driver demand and vehicle operating conditions With this information the TCM can cal culate and perform timely and quality shifts through various output or control devices solenoid pack transmission control relay etc TRANSMISSION IDENTIFICATION Transmission identification numbers are stamped on the left side of the case just above the oil pan sealing surface Fig 1 Refer to this information when ordering replacement parts A label is attached to the transmission case above the stamped numbers The label gives additional information which may also be necessary for identification purposes I
257. ystem using fuel priming plunger Refer to 14 FUEL SYSTEM STANDARD PROCE DURE 4 Connect negative battery cable FUEL RAIL DESCRIPTION WARNING HIGH PRESSURE FUEL LINE DELIVER DIESEL FUEL UNDER EXTREME PRESSURE FROM THE INJECTION PUMP TO THE FUEL INJECTORS THIS MAY BE AS HIGH AS 1600BAR 23 200PSI USE EXTREME CAUTION WHEN INSPECTING FOR HIGH PRESSURE FUEL LEAKS FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE SKIN CAUSING PERSONAL INJURY OR DEATH INSPECT FOR HIGH PRESSURE LEAKS WITH A SHEET OF CARDBOARD WEAR SAFETY GOG GLES AND ADEQUATE PROTECTIVE CLOTHING WHEN SERVICING FUEL SYSTEM The fuel rail is mounted to the cylinder head cover intake manifold Refer to 14 FUEL SYSTEM WARNING Fig 5 OPERATION WARNING HIGH PRESSURE LINES DELIVER DIE SEL FUEL UNDER EXTREME PRESSURE FROM THE INJECTION PUMP TO THE FUEL INJECTORS THIS MAY BE AS HIGH AS 1600BAR 23 200 PSI USE EXTREME CAUTION WHEN INSPECTING FOR HIGH PRESSURE FUEL LEAKS FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENETRATE SKIN CAUSING PERSONAL INJURY OR DEATH INSPECT FOR HIGH PRESSURE FUEL LEAKS WITH A SHEET OF CARDBOARD WEAR SAFETY GOGGLES AND ADEQUATE PROTECTIVE CLOTH ING WHEN SERVICING FUEL SYSTEM The fuel rail stores the fuel for the injectors at high pressure At the same time the pressure oscil lations which are generated due to the high pressure pump delivery and the injection of fuel are dampened by the rail volume The

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