Jeep WG Grand Cherokee (2002) Service Manual

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GROUP TAB LOCATOR

Lubrication & Maintenance

Cooling

7a 8Ea 8Fa 8Ia

11a 14a 19a 21a 25a

Electronic Control Modules Engine Systems Ignition Control Engine

Exhaust System Fuel System Steering - 2.7L - Diesel Transmission and Transfer Case Emissions Control - 2.7L Diesel

Service Manual Comment Forms (Rear of Manual)

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WG LUBRICATION & MAINTENANCE 0a - 1

LUBRICATION & MAINTENANCE

TABLE OF CONTENTS

page page

LUBRICATION & MAINTENANCE

SPECIFICATIONS - FLUID CAPACITIES .......1

INTERNATIONAL SYMBOLS

DESCRIPTION ..........................2

PARTS & LUBRICANT RECOMMENDATION

STANDARD PROCEDURE - PARTS &

LUBRICANT RECOMMENDATIONS .........2

FLUID TYPES

DESCRIPTION

DESCRIPTION - ENGINE COOLANT ........2

DESCRIPTION - HOAT COOLANT ..........3

ENGINE OIL ..........................4

DESCRIPTION - ENGINE OIL .............5

DESCRIPTION ........................5

DESCRIPTION - TRANSFER CASE - NV242 . . 5 DESCRIPTION - TRANSFER CASE - NV247 . . 5 DESCRIPTION - AUTOMATIC

TRANSMISSION FLUID ..................5

DESCRIPTION - AUTOMATIC

TRANSMISSION FLUID - W5J400 ..........6

LUBRICATION & MAINTENANCE

SPECIFICATIONS - FLUID CAPACITIES

DESCRIPTION SPECIFICATION

FUEL TANK 20 U.S. Gallons (76

Liters)****

Engine Oil - with Filter -

2.7L Diesel

Engine Oil - with Filter -

4.0L

Engine Oil - with Filter -

4.7L

Cooling System - 2.7L

Diesel Cooling System - 4.0L 14.1 L (15 qts.)*** Cooling System - 4.7L 13.7 L (14.5 qts.)***

AUTOMATIC TRANSMISSION

Service Fill - 42RE 3.8 L (4.0 qts.)

Service Fill - 545RFE 2WD - 5.2 L (11 pts.)

6.5L (6.9 qts.)

5.7 L (6.0 qts.)

14.2L (15 qts.)***

4WD - 6.2 L (13 pts.)

DESCRIPTION - ENGINE OIL - DIESEL

ENGINES ............................6

OPERATION - AUTOMATIC TRANSMISSION

FLUID ...............................6

FLUID FILL/CHECK LOCATIONS

INSPECTION - FLUID FILL/CHECK

LOCATIONS ..........................6

MAINTENANCE SCHEDULES

DESCRIPTION ..........................6

LIFT POINTS

STANDARD PROCEDURE - HOISTING AND

JACKING RECOMMENDATIONS ...........7

JUMP STARTING

STANDARD PROCEDURE - JUMP STARTING . . 7

EMERGENCY TOW HOOKS

DESCRIPTION ..........................8

TOWING

STANDARD PROCEDURE - TOWING

RECOMMENDATIONS ...................9

DESCRIPTION SPECIFICATION

Service Fill - W5J400 5.0 L (10.6 pts.)

O-haul Fill - 42RE 9.1-9.5 L (19-20 pts.) O-haul Fill - 545RFE 13.33 L (28.0 pts.) O-haul Fill - W5J400 7.7 L (16.3 pts)

Dry fill capacity Depending on type and size of

internal cooler, length and inside diameter of cooler

lines, or use of an auxiliary cooler, these figures may

vary. (Refer to appropriate 21 - TRANSMISSION/

TRANSAXLE/AUTOMATIC/FLUID - STANDARD

PROCEDURE).

TRANSFER CASE NV242 1.35L (2.85 pts.) NV247 1.6L (3.4 pts.)

FRONT AXLE ± 0.3 L (1 oz.) 186 FBI (Model 30) 1.18 L (2.5 pts.)* * With Vari-Lok add 0.07 L (2.5 oz.) of Friction

Modifier.

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LUBRICATION & MAINTENANCE (Continued)

DESCRIPTION SPECIFICATION

REAR AXLE ± 0.3 L (1 oz.) 198 RBI (Model 35) 1.66 L (3.5 pts.)* 226 RBA (Model 44) 2.24 L (4.75 pts.)** * With Trac-lok add 0.07 L (2.5 oz.) of Friction

Modifier. ** With Trac-lok or Vari-Lok, add 0.07 L (2.5 oz.) of

Friction Modifier. *** Includes 0.9L (1.0 qts.) for coolant reservoir. ****Nominal refill capacities are shown. A variation

may be observed from vehicle to vehicle due to manufacturing tolerance and refill procedure.

INTERNATIONAL SYMBOLS

DESCRIPTION

DaimlerChrysler Corporation uses international symbols to identify engine compartment lubricant and fluid inspection and fill locations (Fig. 1).

1 - WHEEL BEARINGS 2 - CHASSIS LUBRICATION 3 - CHASSIS AND WHEEL BEARINGS

When service is required, DaimlerChrysler Corporation recommends that only Mopart brand parts, lubricants and chemicals be used. Mopar provides the best engineered products for servicing DaimlerChrysler Corporation vehicles.

FLUID TYPES

Fig. 2 NLGI Symbol

Fig. 1 INTERNATIONAL SYMBOLS

PARTS & LUBRICANT RECOMMENDATION

STANDARD PROCEDURE - PARTS & LUBRICANT RECOMMENDATIONS

Lubricating grease is rated for quality and usage by the NLGI. All approved products have the NLGI symbol (Fig. 2) on the label. At the bottom NLGI symbol is the usage and quality identification letters. Wheel bearing lubricant is identified by the letter “G”. Chassis lubricant is identified by the latter “L”. The letter following the usage letter indicates the quality of the lubricant. The following symbols indicate the highest quality.

DESCRIPTION

DESCRIPTION - ENGINE COOLANT

ETHYLENE-GLYCOL MIXTURES

CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol.

The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide protection against freezing to -37 deg. C (-35 deg. F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage

is lower than 44 percent, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion.

Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7 deg. C (-90 deg. F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water.

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WG LUBRICATION & MAINTENANCE 0a - 3

FLUID TYPES (Continued)

Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise to as high as 149 deg. C (300) deg. F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22 deg. C (-8 deg. F ).

PROPYLENE-GLYCOL MIXTURES

It’s overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32 deg. C (-26 deg. F). 5 deg. C higher than ethylene-glycol’s freeze point. The boiling point (protection against summer boilover) of propylene-glycol is 125 deg. C (257 deg. F ) at 96.5 kPa (14 psi), compared to 128 deg. C (263 deg. F) for ethylene-glycol. Use of propylene-glycol can result in boil-over or freeze-up on a cooling system designed for ethylene-glycol. Propylene glycol also has poorer heat transfer characteristics than ethylene glycol. This can increase cylinder head temperatures under certain conditions.

Propylene-glycol/ethylene-glycol Mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the various cooling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining freeze point will not be accurate. Both the refractive index and specific gravity differ between ethylene glycol and propy-

lene glycol.

DESCRIPTION - HOAT COOLANT

WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT.

CAUTION: Use of Propylene Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection.

The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air.

The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopart Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% Ethylene Glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution.

CAUTION: MoparT Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection.

COOLANT PERFORMANCE

The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows:

Pure Water-Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion.

100 percent Ethylene-Glycol-The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F).

50/50 Ethylene-Glycol and Water-Is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, yearround in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protec-

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FLUID TYPES (Continued)

tion against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water.

CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol.

COOLANT SELECTION AND ADDITIVES

The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopart Antifreeze/Coolant, 5 Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution.

CAUTION: Do not use coolant additives that are claimed to improve engine cooling.

SAE VISCOSITY

An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities such as 5W-30 or 10W-30. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation (Fig. 3).

Fig. 3 Temperature/Engine Oil Viscosity - 4.7L

ENERGY CONSERVING OIL

An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CONSERVING is located on the label of an engine oil container.

ENGINE OIL

WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA.

API SERVICE GRADE CERTIFIED

Use an engine oil that is API Service Grade Certified. MOPARt provides engine oils that conform to this service grade.

CONTAINER IDENTIFICATION

Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans (Fig. 4).

Fig. 4 API SYMBOL

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FLUID TYPES (Continued)

DESCRIPTION - ENGINE OIL

DESCRIPTION

A multi-purpose, hypoid gear lubricant which conforms to MIL-L-2105C and API GL 5 quality specifications should be used. Mopar Hypoid Gear Lubricant conforms to these specifications.

Fig. 6 API Symbol

API SERVICE GRADE CERTIFIED

Use an engine oil that is API Service Grade Certified. MOPARt provides engine oils that conform to this service grade.

SAE VISCOSITY

An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities such as 5W-30 or 10W-30. These oils are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation (Fig. 5).

FRONT AXLE

• Lubricant is SAE 75W-140 SYNTHETIC.

REAR AXLE

• Lubricant is a thermally stable SAE 80W-90

gear lubricant.

• Lubricant for heavy-duty or trailer tow use is

SAE 75W-140 SYNTHETIC.

NOTE: Trac-lokT and Vari-lokT equipped axles require a friction modifier be added to the lubricant.

DESCRIPTION - TRANSFER CASE - NV242

Recommended lubricant for the NV242 transfer case is Mopart ATF+4, type 9602 Automatic Transmission Fluid.

DESCRIPTION - TRANSFER CASE - NV247

Mopart Transfer Case Lubricant (P/N 05016796) is the only lubricant recommended for the NV247 transfer case.

DESCRIPTION - AUTOMATIC TRANSMISSION FLUID

Fig. 5 Temperature/Engine Oil Viscosity - 4.0L

ENERGY CONSERVING OIL

An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CONSERVING is located on the label of an engine oil container.

CONTAINER IDENTIFICATION

NOTE: Refer to Service Procedures in this group for fluid level checking procedures.

Mopart ATF +4, type 9602, Automatic Transmission Fluid is the recommended fluid for DaimlerChrysler automatic transmissions.

Dexron II fluid IS NOT recommended. Clutch chatter can result from the use of improper fluid.

Mopart ATF +4, type 9602, Automatic Transmission Fluid when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid

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FLUID TYPES (Continued)

condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change.

FLUID ADDITIVES

DaimlerChrysler strongly recommends against the addition of any fluids to the transmission, other than those automatic transmission fluids listed above. Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks.

Various “special” additives and supplements exist that claim to improve shift feel and/or quality. These additives and others also claim to improve converter clutch operation and inhibit overheating, oxidation, varnish, and sludge. These claims have not been supported to the satisfaction of DaimlerChrysler and these additives must not be used. The use of transmission “sealers” should also be avoided, since they may adversely affect the integrity of transmission seals.

DESCRIPTION - AUTOMATIC TRANSMISSION FLUID - W5J400

NOTE: Refer to Service Procedures in this group for fluid level checking procedures.

Shellt 3403 Automatic Transmission Fluid is the recommended fluid for the W5J400 DaimlerChrysler automatic transmission.

Dexron II fluid IS NOT recommended. Clutch

chatter can result from the use of improper fluid.

Shellt 3403 Automatic Transmission Fluid when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown.

This is normal.

FLUID ADDITIVES

additives must not be used. The use of transmission “sealers” should also be avoided, since they may adversely affect the integrity of transmission seals.

DESCRIPTION - ENGINE OIL - DIESEL ENGINES

Use only Diesel Engine Oil meeting standard MIL2104C or API Classification CD or higher or CCML D4, D5.

SAE VISCOSITY GRADE

CAUTION: Low viscosity oils must have the proper API quality or the CCMC G5 designation.

To assure of properly formulated engine oils, it is recommended that SAE Grade 10W-40 engine oils that meet Chrysler material standard MS-6395, be used. European Grade 10W-40 oils are also acceptable.

Oils of the SAE 5W-40 or 8W-80 grade number are preferred when minimum temperatures consistently fall below -12°C.

OPERATION - AUTOMATIC TRANSMISSION FLUID

The automatic transmission fluid is selected based upon several qualities. The fluid must provide a high level of protection for the internal components by providing a lubricating film between adjacent metal components. The fluid must also be thermally stable so that it can maintain a consistent viscosity through a large temperature range. If the viscosity stays constant through the temperature range of operation, transmission operation and shift feel will remain consistent. Transmission fluid must also be a good conductor of heat. The fluid must absorb heat from the internal transmission components and transfer that heat to the transmission case.

FLUID FILL/CHECK LOCATIONS

INSPECTION - FLUID FILL/CHECK LOCATIONS

The fluid fill/check locations and lubrication points are located in each applicable group.

MAINTENANCE SCHEDULES

DESCRIPTION

9Maintenance Schedule Information not included in this section, is located in the appropriate Owner’s Manual.9

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LIFT POINTS

STANDARD PROCEDURE - HOISTING AND JACKING RECOMMENDATIONS

FLOOR JACK

When properly positioned, a floor jack can be used to lift a WJ vehicle (Fig. 7). Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails.

CAUTION: Do not attempt to lift a vehicle with a floor jack positioned under:

• An axle tube.

• Aluminum differential.

• A body side sill.

• A steering linkage component.

• A drive shaft.

• The engine or transmission oil pan.

• The fuel tank.

• A front suspension arm.

HOIST

A vehicle can be lifted with:

• A single-post, frame-contact hoist.

• A twin-post, chassis hoist.

• A ramp-type, drive-on hoist.

NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly (Fig. 7).

WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN A CHASSIS OR DRIVETRAIN COMPONENT IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST.

JUMP STARTING

STANDARD PROCEDURE - JUMP STARTING

WARNING: REVIEW ALL SAFETY PRECAUTIONS AND WARNINGS IN GROUP 8A, BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT. DO NOT JUMP START WHEN MAINTENANCE FREE BATTERY INDICATOR DOT IS YELLOW OR BRIGHT COLOR. DO NOT JUMP START A VEHICLE WHEN THE BATTERY FLUID IS

Fig. 7 Correct Vehicle Lifting Locations

BELOW THE TOP OF LEAD PLATES. DO NOT ALLOW JUMPER CABLE CLAMPS TO TOUCH EACH OTHER WHEN CONNECTED TO A BOOSTER SOURCE. DO NOT USE OPEN FLAME NEAR BATTERY. REMOVE METALLIC JEWELRY WORN ON HANDS OR WRISTS TO AVOID INJURY BY ACCIDENTAL ARCING OF BATTERY CURRENT. WHEN USING A HIGH OUTPUT BOOSTING DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO EXCEED 16 VOLTS. REFER TO INSTRUCTIONS PROVIDED WITH DEVICE BEING USED.

CAUTION: When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can be damaged on either vehicle.

TO JUMP START A DISABLED VEHICLE:

(1) Raise hood on disabled vehicle and visually

inspect engine compartment for:

• Battery cable clamp condition, clean if necessary.

• Frozen battery.

• Yellow or bright color test indicator, if equipped.

• Low battery fluid level.

• Generator drive belt condition and tension.

• Fuel fumes or leakage, correct if necessary.

CAUTION: If the cause of starting problem on disabled vehicle is severe, damage to booster vehicle charging system can result.

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JUMP STARTING (Continued)

(2) When using another vehicle as a booster source, park the booster vehicle within cable reach. Turn off all accessories, set the parking brake, place the automatic transmission in PARK or the manual transmission in NEUTRAL and turn the ignition OFF.

(3) On disabled vehicle, place gear selector in park or neutral and set park brake. Turn off all accessories.

(4) Connect jumper cables to booster battery. RED clamp to positive terminal (+). BLACK clamp to negative terminal (-). DO NOT allow clamps at opposite end of cables to touch, electrical arc will result. Review all warnings in this procedure.

(5) On disabled vehicle, connect RED jumper cable clamp to positive (+) terminal. Connect BLACK jumper cable clamp to engine ground as close to the ground cable attaching point as possible (Fig. 8).

(6) Start the engine in the vehicle which has the booster battery, let the engine idle a few minutes, then start the engine in the vehicle with the discharged battery.

(7) Allow battery in disabled vehicle to charge to at least 12.4 volts (75% charge) before attempting to start engine. If engine does not start within 15 seconds, stop cranking engine and allow starter to cool (15 min.), before cranking again.

DISCONNECT CABLE CLAMPS AS FOLLOWS:

• Disconnect BLACK cable clamp from engine

ground on disabled vehicle.

• When using a Booster vehicle, disconnect BLACK cable clamp from battery negative terminal. Disconnect RED cable clamp from battery positive terminal.

• Disconnect RED cable clamp from battery positive terminal on disabled vehicle.

EMERGENCY TOW HOOKS

DESCRIPTION

WARNING: REMAIN AT A SAFE DISTANCE FROM A VEHICLE THAT IS BEING TOWED VIA ITS TOW HOOKS. THE TOW STRAPS/CHAINS COULD BREAK AND CAUSE SERIOUS INJURY.

Fig. 8 Jumper Cable Clamp Connections

1 - ENGINE GROUND 2 - NEGATIVE JUMPER CABLE 3 - BATTERY NEGATIVE CABLE 4 - POSITIVE JUMPER CABLE 5 - BATTERY POSITIVE CABLE 6 - BATTERY 7 - TEST INDICATOR

CAUTION: Do not crank starter motor on disabled vehicle for more than 15 seconds, starter will overheat and could fail.

Some Jeep vehicles are equipped with front emergency tow hooks (Fig. 9). The tow hooks should be used for EMERGENCYpurposes only.

CAUTION: DO NOT use emergency tow hooks for tow truck hook-up or highway towing.

Fig. 9 Emergency Tow Hooks

1 - TOW HOOK

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WG LUBRICATION & MAINTENANCE 0a - 9

TOWING

STANDARD PROCEDURE - TOWING RECOMMENDATIONS

A vehicle equipped with SAE approved wheel lifttype towing equipment can be used to tow WJ vehicles. When towing a 4WD vehicle using a wheel-lift towing device, use tow dollies under the opposite end of the vehicle. A vehicle with flatbed device can also be used to transport a disabled vehicle (Fig. 10).

Fig. 10 Tow Vehicles With Approved Equipment

SAFETY PRECAUTIONS

CAUTION: The following safety precautions must be observed when towing a vehicle:

• Secure loose and protruding parts.

• Always use a safety chain system that is inde-

pendent of the lifting and towing equipment.

• Do not allow towing equipment to contact the

disabled vehicle’s fuel tank.

• Do not allow anyone under the disabled vehicle

while it is lifted by the towing device.

• Do not allow passengers to ride in a vehicle

being towed.

• Always observe state and local laws regarding

towing regulations.

• Do not tow a vehicle in a manner that could jeopardize the safety of the operator, pedestrians or other motorists.

• Do not attach tow chains, T-hooks, or J-hooks to a bumper, steering linkage, drive shafts or a non-reinforced frame hole.

• Do not tow a heavily loaded vehicle. Use a flatbed device to transport a loaded vehicle.

TWO-WHEEL-DRIVE VEHICLE TOWING

DaimlerChrysler Corporation recommends that a vehicle be towed with the rear end lifted, whenever possible.

WARNING: WHEN TOWING A DISABLED VEHICLE AND THE DRIVE WHEELS ARE SECURED IN A WHEEL LIFT OR TOW DOLLIES, ENSURE THE TRANSMISSION IS IN THE PARK POSITION (AUTOMATIC TRANSMISSION) OR A FORWARD DRIVE GEAR (MANUAL TRANSMISSION).

WARNING: ENSURE VEHICLE IS ON A LEVEL SURFACE OR THE WHEELS ARE BLOCKED TO PREVENT VEHICLE FROM ROLLING.

TWO WHEEL DRIVE TOWING-REAR END LIFTED

CAUTION: Do not use steering column lock to secure steering wheel during towing operation.

2WD vehicles can be towed with the front wheels on the surface for extended distances at speeds not exceeding 48 km/h (30 mph).

(1) Attach wheel lift device to rear wheels.

(2) Place the transmission in neutral.

(3) Raise vehicle to towing position.

(4) Attach safety chains. Route chains so not to interfere with tail pipe when vehicle is lifted.

(5) Turn the ignition switch to the OFF position to unlock the steering wheel.

CAUTION: Do not use steering column lock to secure steering wheel during towing operation.

(6) Secure steering wheel in straight ahead position with a clamp device designed for towing.

(7) Place transmission in park.

TWO WHEEL DRIVE TOWING-FRONT END LIFTED

CAUTION: Many vehicles are equipped with air dams, spoilers, and/or ground effect panels. To avoid component damage, a wheel-lift towing vehicle or a flat-bed hauling vehicle is recommended.

(1) Attach wheel lift device to rear wheels.

(2) Place the transmission in neutral.

(3) Raise the rear of the vehicle off the ground and install tow dollies under rear wheels.

(4) Attach wheel lift device to front wheels and raise vehicle to towing position.

(5) Attach the safety chains.

CAUTION: Do not use steering column lock to secure steering wheel during towing operation.

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TOWING (Continued)

(6) Turn the ignition switch to the OFF position to

unlock the steering wheel.

(7) Secure steering wheel in straight ahead posi-

tion with a clamp device designed for towing.

(8) Place transmission in park.

FOUR-WHEEL-DRIVE VEHICLE TOWING

DaimlerChrysler Corporation recommends that a 4WD vehicle be transported on a flat-bed device. A Wheel-lift device can be used provided the trailing

wheels are off the ground and positioned in tow dollies.

WARNING: WHEN TOWING A DISABLED VEHICLE AND THE DRIVE WHEELS ARE SECURED IN A WHEEL LIFT OR TOW DOLLIES, ENSURE THE TRANSMISSION IS IN THE PARK POSITION.

CAUTION: Many vehicles are equipped with air dams, spoilers, and/or ground effect panels. To avoid component damage, a wheel-lift towing vehicle or a flat-bed hauling vehicle is recommended.

FOUR WHEEL DRIVE TOWING—REAR END LIFTED

(5) Attach safety chains. Route chains so not to

interfere with tail pipe when vehicle is lifted.

(6) Turn the ignition switch to the OFF position to

unlock the steering wheel.

CAUTION: Do not use steering column lock to secure steering wheel during towing operation.

(7) Secure steering wheel in straight ahead posi-

tion with a clamp device designed for towing.

(8) Place transmission in park.

FOUR WHEEL DRIVE TOWING—FRONT END LIFTED

WARNING: ENSURE VEHICLE IS ON A LEVEL SURFACE OR THE WHEELS ARE BLOCKED TO PREVENT VEHICLE FROM ROLLING.

(1) Attach wheel lift device to rear wheels. (2) Place the transmission in neutral. (3) Raise the rear of the vehicle off the ground and

install tow dollies under rear wheels.

(4) Attach wheel lift device to front wheels and

raise vehicle to towing position.

(5) Attach the safety chains.

WARNING: ENSURE VEHICLE IS ON A LEVEL SURFACE OR THE WHEELS ARE BLOCKED TO PREVENT VEHICLE FROM ROLLING.

(1) Attach wheel lift device to front wheels.

(2) Place the transmission in neutral.

(3) Raise the front of the vehicle off the ground

and install tow dollies under front wheels.

(4) Attach wheel lift device to rear wheels and raise vehicle to towing position.

CAUTION: Do not use steering column lock to secure steering wheel during towing operation.

(6) Turn the ignition switch to the OFF position to

unlock the steering wheel.

(7) Secure steering wheel in straight ahead posi-

tion with a clamp device designed for towing.

(8) Place transmission in park.

Page 12

WG COOLING - 2.7L DIESEL 7a - 1

COOLING - 2.7L DIESEL

TABLE OF CONTENTS

page page

COOLING - 2.7L DIESEL

OPERATION—COOLING SYSTEM ...........1

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - PRELIMINARY

CHECKS .............................1

COOLING - 2.7L DIESEL

OPERATION—COOLING SYSTEM

The cooling system regulates engine operating temperature. It allows the engine to reach normal operating temperature as quickly as possible. It also maintains normal operating temperature and prevents overheating.

The cooling system also provides a means of heating the passenger compartment and cooling the automatic transmission fluid (if equipped). The cooling system is pressurized and uses a centrifugal water pump to circulate coolant throughout the system.

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - PRELIMINARY

CHECKS

ENGINE COOLING SYSTEM OVERHEATING

Establish what driving conditions caused the complaint. Abnormal loads on the cooling system such as the following may be the cause:

• PROLONGED IDLE

• VERY HIGH AMBIENT TEMPERATURE

• SLIGHT TAIL WIND AT IDLE

• SLOW TRAFFIC

• TRAFFIC JAMS

• HIGH SPEED OR STEEP GRADES

Driving techniques that avoid overheating are:

• Idle with A/C off when temperature gauge is at

end of normal range.

DIAGNOSIS AND TESTING - COOLING

SYSTEM .............................2

ACCESSORY DRIVE .......................5

ENGINE ................................9

• Increasing engine speed for more air flow is rec-

ommended.

TRAILER TOWING:

Consult Trailer Towing section of owners manual.

Do not exceed limits.

AIR CONDITIONING; ADD-ON OR AFTER MARKET:

A maximum cooling package should have been ordered with vehicle if add-on or after market A/C is installed. If not, maximum cooling system components should be installed for model involved per manufacturer’s specifications.

RECENT SERVICE OR ACCIDENT REPAIR:

Determine if any recent service has been performed on vehicle that may effect cooling system. This may be:

• Engine adjustments (incorrect timing)

• Slipping engine accessory drive belt(s)

• Brakes (possibly dragging)

• Changed parts. Incorrect water pump or pump

rotating in wrong direction due to belt not correctly routed

• 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 complaint, (Refer to 7 - COOLING - DIAGNOSIS AND TESTING)

Page 13

7a - 2 COOLING - 2.7L DIESEL WG

COOLING - 2.7L DIESEL (Continued)

DIAGNOSIS AND TESTING - COOLING SYSTEM

COOLING SYSTEM DIAGNOSIS—DIESEL ENGINE

CONDITION POSSIBLE CAUSES CORRECTION

TEMPERATUREGAUGE READS LOW

TEMPERATURE GAUGE READS HIGH. COOLANT MAY OR MAY NOT BE LEAKING FROM SYSTEM

1. Vehicle is equipped with a heavy duty cooling system.

2. Temperature gauge not connected 2. Connect gauge.

3. Temperature gauge connected but not operating.

4. Coolant level low. 4. Fill cooling system. (Refer to 7 -

1. Vehicle overloaded, high ambient (outside) temperatures with A/C turned on, stop and go driving or prolonged operation at idle speeds.

2. Temperature gauge not functioning correctly.

3. Air traped in cooling 3. Drain cooling system (Refer to 7 -

4. Radiator cap faulty. 4. Replace radiator cap.

5. Plugged A/C or radiator cooling fins. 5. Clean all debre away from A/C and

6. Coolant mixture incorrect. 6. Drain cooling system (Refer to 7 -

7. Thermostat stuck shut. 7. Replace thermostat.

8. Bug screen or winter front being used.

9. Viscous fan drive not operating properly.

10. Cylinder head gasket leaking. 10. Check for leaking head gaskets

11. Heater core leaking. 11. Replace heater core.

12. cooling system hoses leaking. 12. Tighten clamps or Replace hoses.

13. Brakes dragging. 13. Check brakes. (Refer to 5 -

1. None. System operating normaly.

3. Check gauge. Refer (Refer to 8 ELECTRICAL/INSTRUMENT CLUSTER

- DIAGNOSIS AND TESTING)

COOLING - STANDARD PROCEDURE)

1. Temporary condition, repair not required. Notify customer of vehicle operation instructions located in Owners Manual.

2. Check gauge. (Refer to 8 ELECTRICAL/INSTRUMENT CLUSTER

- DIAGNOSIS AND TESTING)

COOLING - STANDARD PROCEDURE) and refill (Refer to 7 - COOLING STANDARD PROCEDURE)

radiator cooling fins.

COOLING - STANDARD PROCEDURE) refill with correct mixture (Refer to 7 COOLING - STANDARD PROCEDURE).

8. Remove bug screen or winter front.

9. Check viscous fan (Refer to 7 COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - DIAGNOSIS AND TESTING)

(Refer to 7 - COOLING - DIAGNOSIS AND TESTING).

BRAKES/HYDRAULIC/MECHANICAL DIAGNOSIS AND TESTING)

Page 14

WG COOLING - 2.7L DIESEL 7a - 3

COOLING - 2.7L DIESEL (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

TEMPERATURE GAUGE READING INCONSISTENT ( ERRATIC, CYCLES OR FLUCTUATES)

RADIATOR CAP LEAKING STEAM AND /OR COOLANT INTO RESERVOIR BOTTLE. (TEMPERATURE GAUGE MAY READ HIGH)

1. Heavy duty cooling system, extream cold ambient (outside) temperature or heater blower motor in high position.

2. Temperature gauge or gauge sensor defective.

3. Temporary heavy usage or load. 3. None. Normal condition.

4. Air traped in cooling system. 4. Fill cooling system (Refer to 7 -

5. Water pump 5. Replace water pump.

6. Air leak on suction side of water pump.

1. Radiator cap defective. 1. Replace radiator cap.

2. Radiator neck surface damaged. 2. Replace radiator.

1. None. System operating normaly.

2. Check gauge. (Refer to 8 ELECTRICAL/INSTRUMENT CLUSTER

- DIAGNOSIS AND TESTING)

COOLING - STANDARD PROCEDURE).

6. Check for leak. (Refer to 7 COOLING - DIAGNOSIS AND TESTING)

HOSE OR HOSES COLLAPSE WHEN ENGINE IS COOLING.

NOISY FAN 1. Fan blade(s) loose, damaged. 1. Replace fan blade assembly.

INADEQUATE AIR CONDITIONER PERFORMANCE (COOLING SYSTEM SUSPECTED)

1. Vacuum created in cooling system on engine cool-down is not being relieved through coolant reservior/overflow system.

2. Thermal viscous fan drive. 2. None. Normal condition.

3. Fan blades striking surrounding objects.

4. Thermal viscous fan drive bearing. 4. Replace viscous fan drive assembly.

5. Obstructed air flow through radiator. 5. Remove obstruction.

1. Radiator and/or A/C condenser air flow obstructed.

2. Thermal viscous fan drive not working.

3. Air seals around radiator damaged or missing.

1. Replace radiator cap, check vent hose between radiator and reservoir bottle for blockage also check reservoir bottle vent for blockage.

3. Locate contact point and repair as necessary.

1. Remove obstruction and/or clean.

2. Check fan drive. (Refer to 7 COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - DIAGNOSIS AND TESTING)

3. Inspect air seals, repair or replace as necessary.

Page 15

7a - 4 COOLING - 2.7L DIESEL WG

COOLING - 2.7L DIESEL (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

INADEQUATE HEATER PERFORMANCE. GUAGE MAY OR MAY NOT READ LOW.

HEAT ODOR 1. Damaged or missing drive line heat

1. Heavy duty cooling system, and cooler ambient temperatures.

2. Obstruction in heater hoses. 2. Remove hoses, remove obstruction.

3. Water pump damaged. 3. Replace water pump.

shields.

2. Thermal viscous fan drive damaged. 2. Check thermal viscous fan drive.

1. None. Normal condition.

1. Repair or replace damaged or missing heat shields.

(Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH DIAGNOSIS AND TESTING)

Page 16

WG ACCESSORY DRIVE 7a - 5

ACCESSORY DRIVE

TABLE OF CONTENTS

page page

DRIVE BELTS

DIAGNOSIS AND TESTING - ACCESSORY

DRIVE BELT ..........................5

REMOVAL .............................7

DRIVE BELTS

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. 1), are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced (Fig. 1). 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.

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 contamination, alignment, glazing, or excessive end play.

INSTALLATION ..........................7

BELT TENSIONERS

DESCRIPTION ..........................8

OPERATION ............................8

Fig. 1 Belt Wear Patterns

1 - NORMAL CRACKS BELT OK 2 - NOT NORMAL CRACKS REPLACE BELT

Page 17

7a - 6 ACCESSORY DRIVE WG

DRIVE BELTS (Continued)

ACCESSORY DRIVE BELT DIAGNOSIS CHART

CONDITION POSSIBLE CAUSES CORRECTION

RIB CHUNKING (One or more ribs has separated from belt body)

RIB OR BELT WEAR 1. Pulley misaligned 1. Align pulley(s)

BELT SLIPS 1. Belt slipping because of

1. Foreign objects imbedded in pulley grooves.

2. Installation damage 2. Replace belt

2. Abrasive environment 2. Clean pulley(s). Replace belt if

3. Rusted pulley(s) 3. Clean rust from pulley(s)

4. Sharp or jagged pulley groove tips

5. Belt rubber deteriorated 5. Replace belt

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. Remove foreign objects from pulley grooves. Replace belt.

necessary

4. Replace pulley. Inspect belt.

1. Inspect/Replace tensioner if necessary

2. Replace belt and clean pulleys

3. Replace faulty component or bearing

4. Replace belt.

LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley

groove

9GROOVE JUMPING9 (Belt does not maintain correct position on pulley)

BELT BROKEN (Note: Identify and correct problem before new belt is installed)

2. Pulley groove tip has worn away rubber to tensile member

1. Incorrect belt tension 1. Inspect/Replace tensioner if

2. Pulley(s) not within design tolerance

3. Foreign object(s) in grooves 3. Remove foreign objects from

4. Pulley misalignment 4. Align component

5. Belt cordline is broken 5. Replace belt

1. Incorrect belt tension 1. Replace Inspect/Replace

2. Tensile member damaged during belt installation

3. Severe misalignment 3. Align pulley(s)

4. Bracket, pulley, or bearing failure 4. Replace defective component

1. Replace belt

2. Replace belt

necessary

2. Replace pulley(s)

grooves

tensioner if necessary

2. Replace belt

and belt

Page 18

WG ACCESSORY DRIVE 7a - 7

DRIVE BELTS (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

NOISE (Objectional squeal, squeek, or rumble is heard or felt while drive belt is in operation)

TENSION SHEETING FABRIC FAILURE (Woven fabric on outside, circumference of belt has cracked or separated from body of belt)

CORD EDGE FAILURE (Tensile member exposed at edges of belt or separated from belt body)

1. Incorrect belt tension 1. Inspect/Replace tensioner if necessary

2. Bearing noise 2. Locate and repair

3. Belt misalignment 3. Align belt/pulley(s)

4. Belt to pulley mismatch 4. Install correct belt

5. Driven component induced

vibration

6. System resonent frequency

induced vibration

1. Tension sheeting contacting

stationary object

2. Excessive heat causing woven

fabric to age

3. Tension sheeting splice has

fractured

1. Incorrect belt tension 1. Inspect/Replace tensioner if

2. Belt contacting stationary object 2. Replace belt

3. Pulley(s) out of tolerance 3. Replace pulley

4. Insufficient adhesion between

tensile member and rubber matrix

5. Locate defective driven component and repair

6. Vary belt tension within specifications

1. Correct rubbing condition

2. Replace belt

3. Replace belt

necessary

4. Replace belt

REMOVAL

CAUTION: Do not attempt to check belt tension with

a belt tension gauge on vehicles equipped with an automatic belt tensioner.

NOTE: The belt routing schematics are published from the latest information available at the time of publication. If anything differs between these schematics and the Belt Routing Label, use the schematics on Belt Routing Label.This label is located in the engine compartment.

(1) A 3/8 inch square hole is provided in the automatic belt tensioner. Attach a 3/8 inch drive-long handle ratchet to this hole.

(2) Rotate ratchet and tensioner assembly counterclockwise (as viewed from front) until tension has been relieved from belt.

(3) Remove belt from water pump pulley first. (4) Remove belt from vehicle.

INSTALLATION

CAUTION: When installing the accessory drive belt, the belt must be the correct length and routed correctly. If not, engine may overheat due to water pump rotating in wrong direction.

(1) Position drive belt over all pulleys except

water pump pulley (Fig. 2).

(2) Attach a 3/8 inch ratchet to tensioner.

(3) Rotate ratchet and belt tensioner counterclockwise. Place belt over water pump pulley. Let tensioner rotate back into place. Remove ratchet. Be sure belt is properly seated on all pulleys.

Page 19

7a - 8 ACCESSORY DRIVE WG

DRIVE BELTS (Continued)

BELT TENSIONERS

DESCRIPTION

CAUTION: Do not attempt to check belt tension with a belt tension gauge on vehicles equipped with an automatic belt tensioner.

Drive belts on all engines are equipped with a spring loaded automatic belt tensioner. This tensioner maintains constant belt tension at all times and requires no maintenance or adjustment.

OPERATION

WARNING: THE AUTOMATIC BELT TENSIONER ASSEMBLY IS SPRING LOADED. DO NOT ATTEMPT TO DISASSEMBLE THE TENSIONER ASSEMBLY.

The automatic belt tensioner maintains correct belt tension using a coiled spring within the tensioner housing. The spring applies pressure to the tensioner

Fig. 2 ACCESSORY BELT ROUTING

1 - VISCOUS HEATER 2 - POWER STEERING PUMP 3 - AC COMPRESSOR 4 - AUTOMATIC BELT TENSIONER 5 - VIBRATION DAMPER/CRANKSHAFT PULLEY 6 - WATER PUMP PULLEY 7 - GENERATOR 8 - IDLER PULLEYS

arm pressing the arm into the belt, tensioning the belt.

If a new belt is being installed, the arrow must be 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:

• The wrong belt being installed (incorrect length/

width)

• Worn bearings on an engine accessory (A/C compressor, power steering pump, water pump, idler pulley or generator)

• A pulley on an engine accessory being loose

• Misalignment of an engine accessory

• Belt incorrectly routed.

Page 20

WG ENGINE 7a - 9

ENGINE

TABLE OF CONTENTS

page page

COOLANT

DESCRIPTION ..........................9

DIAGNOSIS AND TESTING - COOLING

SYSTEM LEAKS ......................10

STANDARD PROCEDURE

STANDARD PROCEDURE - ADDING

ADDITIONAL COOLANT.................11

STANDARD PROCEDURE - DRAINING

COOLING SYSTEM ....................12

STANDARD PROCEDURE - REFILLING

COOLING SYSTEM ....................12

COOLANT RECOVERY PRESSURE

CONTAINER

DESCRIPTION .........................12

OPERATION ...........................12

REMOVAL .............................13

INSTALLATION .........................13

ENGINE COOLANT TEMP SENSOR

REMOVAL .............................13

INSTALLATION .........................13

ENGINE COOLANT THERMOSTAT

REMOVAL .............................14

INSTALLATION .........................14

COOLANT

WATER PUMP

REMOVAL .............................14

INSTALLATION .........................15

RADIATOR FAN

DESCRIPTION .........................15

OPERATION ...........................16

REMOVAL .............................17

INSTALLATION .........................18

RADIATOR PRESSURE CAP

DESCRIPTION .........................19

OPERATION ...........................20

DIAGNOSIS AND TESTING - RADIATOR

PRESSURE CAP ......................20

CLEANING ............................20

INSPECTION ..........................20

RADIATOR

DESCRIPTION .........................20

DIAGNOSIS AND TESTING - RADIATOR FLOW

TEST ...............................20

REMOVAL .............................21

CLEANING ............................21

INSTALLATION .........................22

cause the engine to overheat because the specific heat of antifreeze is lower than that of water.

DESCRIPTION

Coolant flows through the engine water jackets and cylinder heads absorbing heat produced by the engine during operation. The coolant carries heat to the radiator and heater core. Here it is transferred to ambient air passing through the radiator and heater core fins.

is lower than 44 percent, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion.

100 Percent Ethylene-Glycol—Should Not Be Used in Chrysler Vehicles

Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise to as high as 149 deg. C (300 deg. F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22 deg. C (-8 deg. F ).

Propylene-glycol Formulations—Should Not Be Used in Chrysler Vehicles

Propylene-glycol formulations do not meet Chrysler coolant specifications. It’s overall effec-

tive temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32 deg. C (-26 deg. F). 5 deg. C higher than ethylene-glycol’s freeze point. The boiling point (protection against summer boil-over) of propylene-

Page 21

7a - 10 ENGINE WG

COOLANT (Continued)

glycol is 125 deg. C (257 deg.F)at96.5 kPa (14 psi), compared to 128 deg. C (263 deg. F) for ethylene-glycol. Use of propylene-glycol can result in boil-over or freeze-up in Chrysler vehicles, which are designed for ethylene-glycol. Propylene glycol also has poorer heat transfer characteristics than ethylene glycol. This can increase cylinder head temperatures under certain conditions.

Propylene-glycol/Ethylene-glycol Mixtures—Should Not Be Used in Chrysler Vehicles

CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol.

Fig. 1 Leak Detection Using Black Light—Typical

1 - TYPICAL BLACK LIGHT TOOL

DIAGNOSIS AND TESTING - COOLING SYSTEM LEAKS

ULTRAVIOLET LIGHT METHOD

A leak detection additive is available through the parts department that can be added to cooling sys-

tem. The additive is highly visible under ultraviolet light (black light). Pour one ounce of additive into cooling system. Place heater control unit in HEAT position. Start and operate engine until radiator upper hose is warm to touch. Aim the commercially available black light tool at components to be checked. If leaks are present, black light will cause additive to glow a bright green color.

The black light can be used in conjunction with a pressure tester to determine if any external leaks exist (Fig. 1).

PRESSURE TESTER METHOD

The engine should be at normal operating temperature. Recheck the system cold if cause of coolant loss is not located during the warm engine examination.

WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING.

Carefully remove coolant recovery pressure container cap and check coolant level. Push down on cap to disengage it from stop tabs. Wipe inside of con-

tainer and examine lower inside sealing seat for nicks, cracks, paint, dirt and solder residue. Inspect radiator-to- pressure container hose for internal obstructions. Insert a wire through the hose to be sure it is not obstructed.

Inspect cams on outside of pressure container. If cams are damaged, seating of pressure cap valve and tester seal will be affected.

Attach pressure tester (7700 or an equivalent) to coolant pressure container (Fig. 2).

Operate tester pump to apply 103.4 kPa (15 psi) pressure to system. If hoses enlarge excessively or bulges while testing, replace as necessary. Observe gauge pointer and determine condition of cooling system according to following criteria:

Holds Steady: If pointer remains steady for two minutes, serious coolant leaks are not present in system. However, there could be an internal leak that does not appear with normal system test pressure. If it is certain that coolant is being lost and leaks cannot be detected, inspect for interior leakage or perform Internal Leakage Test.

Drops Slowly: Indicates a small leak or seepage is occurring. Examine all connections for seepage or slight leakage with a flashlight. Inspect radiator, hoses, gasket edges and heater. Seal small leak holes with a Sealer Lubricant (or equivalent). Repair leak holes and inspect system again with pressure applied.

Drops Quickly: Indicates that serious leakage is occurring. Examine system for external leakage. If

Page 22

WG ENGINE 7a - 11

COOLANT (Continued)

the result of a cylinder head gasket leak or crack in engine. Repair as necessary.

If there is not an immediate pressure increase, pump the Pressure Tester. Do this until indicated pressure is within system range of 110 kPa (16 psi). Fluctuation of gauge pointer indicates compression or combustion leakage into cooling system.

Because the vehicle is equipped with a catalytic converter, do not remove spark plug cables or short out cylinders to isolate compression leak.

If the needle on dial of pressure tester does not fluctuate, race engine a few times to check for an abnormal amount of coolant or steam. This would be emitting from exhaust pipe. Coolant or steam from exhaust pipe may indicate a faulty cylinder head gasket, cracked engine cylinder block or cylinder head.

A convenient check for exhaust gas leakage into cooling system is provided by a commercially available Block Leak Check tool. Follow manufacturers instructions when using this product.

Fig. 2 PRESSURE TESTING COOLING SYSTEM

1 - COOLANT PRESSURE TESTER 2 - COOLANT PRESSURE CONTAINER

leaks are not visible, inspect for internal leakage. Large radiator leak holes should be repaired by a reputable radiator repair shop.

INTERNAL LEAKAGE INSPECTION

Remove engine oil pan drain plug and drain a small amount of engine oil. If coolant is present in the pan, it will drain first because it is heavier than oil. An alternative method is to operate engine for a short period to churn the oil. After this is done, remove engine dipstick and inspect for water globules. Also inspect transmission dipstick for water globules and transmission fluid cooler for leakage.

WARNING: WITH RADIATOR PRESSURE TESTER TOOL INSTALLED ON RADIATOR, DO NOT ALLOW PRESSURE TO EXCEED 110 KPA (20 PSI). PRESSURE WILL BUILD UP QUICKLY IF A COMBUSTION LEAK IS PRESENT. TO RELEASE PRESSURE, ROCK TESTER FROM SIDE TO SIDE. WHEN REMOVING TESTER, DO NOT TURN TESTER MORE THAN 1/2 TURN IF SYSTEM IS UNDER PRESSURE.

Operate engine without pressure cap on coolant container until thermostat opens. Attach a Pressure Tester to container. If pressure builds up quickly it indicates a combustion leak exists. This is usually

COMBUSTION LEAKAGE TEST - WITHOUT PRESSURE TESTER

DO NOT WASTE reusable coolant. If solution is clean, drain coolant into a clean and suitably marked container for reuse.

WARNING: DO NOT REMOVE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN RADIATOR DRAIN WITH SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR.

Drain sufficient coolant to allow thermostat removal.

Remove accessory drive belt.

Add coolant to pressure container to bring level to within 6.3 mm (1/4 in) of top of thermostat housing.

CAUTION: Avoid overheating. Do not operate engine for an excessive period of time. Open draincock immediately after test to eliminate boil over.

Start engine and accelerate rapidly three times, to approximately 3000 rpm while observing coolant. If internal engine combustion gases are leaking into cooling system, bubbles will appear in coolant. If bubbles do not appear, internal combustion gas leakage is not present.

STANDARD PROCEDURE

STANDARD PROCEDURE - ADDING ADDITIONAL COOLANT

The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopart Antifreeze/Coolant, 5

Page 23

7a - 12 ENGINE WG

COOLANT (Continued)

Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution.

CAUTION: Do not use coolant additives that are claimed to improve engine cooling.

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.

(1) DO NOT remove coolant recovery pressure container cap first. With engine cold, raise vehicle on a hoist and locate radiator draincock.

engine is cold. Coolant level in a warm engine will be higher due to thermal expansion. To

purge the cooling system of all air, this heat up/cool down cycle (adding coolant to cold engine) must be performed three times. Add necessary coolant to raise container level to the FULL mark after each cool down period.

COOLANT RECOVERY PRESSURE CONTAINER

DESCRIPTION

A pressurized, plastic coolant container is used with this cooling system (Fig. 3). The container is located at the right-rear side of the engine compartment and is mounted as the highest point of the cooling system.

NOTE: Radiator draincock is located on the right/ lower side of radiator facing to rear of vehicle.

(2) Attach one end of a hose to the draincock. Put the other end into a clean container. Open draincock and drain coolant from radiator. This will empty the coolant recovery pressure container first. The coolant

does not have to be removed from the container unless the system is being refilled with a fresh mixture. When container is empty, remove cap and continue draining cooling system.

To drain the engine of coolant, remove the cylinder block drain plug located on the side of cylinder block.

STANDARD PROCEDURE - REFILLING COOLING SYSTEM

(1) Tighten the radiator drain and the cylinder block drain plug(s) (if removed).

(2) Fill system using a 50/50 mixture of ethyleneglycol antifreeze and low mineral content water. Fill radiator to top and add sufficient coolant to the coolant recovery pressure container to raise level to FULL mark.

(3) With heater control unit in the HEAT position, operate engine with container cap in place.

(4) After engine has reached normal operating temperature, shut engine off and allow it to cool. When engine is cooling down, coolant will be drawn into the radiator from the pressure container.

(5) Add coolant to pressure container as necessary.

Only add coolant to the container when the

Fig. 3 COOLANT RECOVERY PRESSURE

CONTAINER

1 - LOW COOLANT LEVEL SENSOR 2 - COOLANT RECOVERY HOSE 3 - COOLANT RECOVERY PRESSURE CONTAINER 4 - OVERFLOW HOSE

OPERATION

The location of the container allows any air or vapor exceeding the pressure/vent cap rating to escape through the cap. Coolant flows through the container at all times during engine operation whether the engine is cold or at normal operating temperature. The coolant container is equipped with a pressure/vent cap. For more information (Refer to 7

Page 24

WG ENGINE 7a - 13

COOLANT RECOVERY PRESSURE CONTAINER (Continued)

- COOLING/ENGINE/RADIATOR PRESSURE CAP DESCRIPTION)

REMOVAL

WARNING: DO NOT OPEN COOLING SYSTEM UNLESS COOLANT TEMPERATURE IS BELOW 90C (194°F). OPEN CONTAINER SLOWLY AND RELEASE PRESSURE. STORE COOLANT IN PROPER CONTAINERS ONLY. WEAR PROTECTIVE GLOVES, CLOTHING AND EYE WEAR. RISK OF INJURY TO SKIN AND EYES WITH HOT COOLANT WHICH SPLASHES OUT. RISK OF POISONING FROM SWALLOWING COOLANT.

NOTE: Turn container cap carefully as far as first detent, release pressure, then unscrew cap.

(1) Release cooling system pressure. (2) Disconnect sensor electrical connector (Fig. 3). (3) Remove radiator over flow hose (Fig. 3). (4) Remove cooling system recovery hose (Fig. 3). (5) Remove container retaining bolts.

(3) Partailly drain coolant system (Refer to 7 COOLING/ENGINE/COOLANT - STANDARD PROCEDURE).

(4) Unplug coolant temperature sensor electrical connector.

NOTE: Capture any residual coolant that may flow.

(5) Remove coolant temperature sensor (Fig. 4).

INSTALLATION

(1) Position coolant container and install retaining

bolts (Fig. 3).

(2) Properly route and install coolant recovery hose

(Fig. 3).

(3) Properly route and install radiator overflow

hose (Fig. 3).

(4) Connect sensor electrical connector (Fig. 3).

(5) Refill system with proper coolant mixture to proper level (Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE).

(6) Start engine and inspect for leaks.

ENGINE COOLANT TEMP SENSOR

REMOVAL

WARNING: RISK OF INJURY TO SKIN AND EYES FROM SCALDING WITH HOT COOLANT. RISK OF POISONING FROM SWALLOWING COOLANT. DO NOT OPEN COOLING SYSTEM UNLESS COOLANT TEMPERATURE IS BELOW 90°C. OPEN CAP SLOWLY TO RELEASE PRESSURE. STORE COOLANT IN SUITABLE AND APPROPRIATELY MARKED CONTAINER. WEAR PROTECTIVE GLOVES, CLOTHES AND EYE WEAR.

(1) Disconnect negative battery cable.

(2) Remove engine cover (Refer to 9 - ENGINE REMOVAL).

Fig. 4 ENGINE COOLANT TEMPERATURE SENSOR

1 - RETAINING CLAMP 2 - ENGINE COOLANT TEMPERATURE SENSOR

INSTALLATION

WARNING: RISK OF INJURY TO SKIN AND EYES FROM SCALDING WITH HOT COOLANT. RISK OF POISONING FROM SWALLOWING COOLANT. DO NOT OPEN COOLING SYSTEM UNLESS COOLANT TEMPERATURE IS BELOW 90°C (194°F). OPEN CAP SLOWLY TO RELEASE PRESSURE. STORE COOLANT IN SUITABLE AND APPROPRIATELY MARKED CONTAINER. WEAR PROTECTIVE GLOVES, CLOTHES AND EYE WEAR.

(1) Position and install coolant temperature sensor

(Fig. 4).

(2) Connect coolant temperature sensor electrical

connector (Fig. 4).

(3) Refill coolant system to proper level with proper mixture of coolant (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE).

(4) Install engine cover (Refer to 9 - ENGINE INSTALLATION).

(5) Connect negative battery cable.

Page 25

7a - 14 ENGINE WG

ENGINE COOLANT TEMP SENSOR (Continued)

WARNING: USE EXTREME CAUTION WHEN ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH FAN. DO NOT PUT YOUR HANDS NEAR PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHES.

(6) Start engine and inspect for leaks.

ENGINE COOLANT THERMOSTAT

REMOVAL

WARNING: RISK OF INJURY TO SKIN AND EYES FROM SCALDING WITH HOT COOLANT. RISK OF POISONING FROM SWALLOWING COOLANT. DO NOT OPEN COOLING SYSTEM UNLESS COOLANT TEMPERATURE IS BELOW 90°C (194°F). OPEN CAP SLOWLY TO RELEASE PRESSURE. STORE COOLANT IN SUITABLE AND APPROPRIATELY MARKED CONTAINER. WEAR PROTECTIVE GLOVES, CLOTHES AND EYE WEAR.

NOTE: Inspect condition of all clamps and hoses, replace as necessary.

(1) Disconnect negative battery cable. (2) Remove engine cover (Refer to 9 - ENGINE -

REMOVAL).

(3) Drain engine coolant (Refer to 7 - COOLING/

ENGINE/COOLANT - STANDARD PROCEDURE).

(4) Remove bracket for fuel line. (5) Remove coolant hoses and vent hose from ther-

mostat housing.

(6) Remove thermostat housing (Fig. 5). (7) Remove thermostat from housing. (8) Clean all sealing surfaces.

1 - VENT HOSE 2 - THERMOSTAT HOUSING 3 - COOLANT HOSE 4 - FUEL LINE BRACKET 5 - UPPER RADIATOR HOSE

(8) Fill coolant system to proper level with appropriate coolant mixture (Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE).

WARNING: USE EXTREME CAUTION WHEN ENGINE IS OPERATING. DO NOT STAND IN DIRECT LINE WITH FAN. DO NOT PUT YOUR HANDS NEAR PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHES.

Fig. 5 THERMOSTAT ASSEMBLY

INSTALLATION

(1) Clean all sealing surfaces.

(2) Position thermostat in housing and install thermostat housing (Fig. 5). Tighten bolts to 9N·m (80 lbs.in.).

NOTE: Inspect condition of all clamps and hoses, replace as necessary.

(3) Connect coolant hoses and vent hose (Fig. 5).

(4) Install bracket for fuel line (Fig. 5).

(5) Close coolant drain.

(6) Install engine cover (Refer to 9 - ENGINE INSTALLATION).

(7) Connect negative battery cable.

(9) Start engine and inspect for leaks.

WATER PUMP

REMOVAL

WARNING: RISK OF INJURY TO SKIN AND EYES FROM SCALDING WITH HOT COOLANT. RISK OF POISONING FROM SWALLOWING COOLANT. DO NOT OPEN COOLING SYSTEM UNLESS COOLANT TEMPERATURE IS BELOW 90°C (194°F). OPEN CAP SLOWLY TO RELEASE PRESSURE. STORE COOLANT IN SUITABLE AND APPROPRIATELY MARKED CONTAINER. WEAR PROTECTIVE GLOVES, CLOTHES AND EYE WEAR.

(1) Disconnect negative battery cable.

Page 26

WG ENGINE 7a - 15

WATER PUMP (Continued)

(2) Remove engine cover (Refer to 9 - ENGINE REMOVAL).

(3) Drain engine coolant (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE).

(4) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL).

(5) Disconnect coolant hoses at water pump.

(6) Remove idler pulley.

(7) Remove water pump and clean sealing surfaces (Fig. 6).

INSTALLATION

(1) Clean all sealing surfaces.

(2) Position and install waterpump (Fig. 6). Tighten M6 bolts to 14N·m (124 lbs. in.) and M8 bolts to 20N·m (177 lbs. in.).

(3) Install idler pulley. Tighten bolt to 35N·m (26 lbs. ft.).

(4) Install coolant hoses.

(5) Install accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).

(6) Close coolant drain.

(7) Install engine cover (Refer to 9 - ENGINE INSTALLATION).

(8) Connect negative battery cable.

(9) Fill coolant system to proper level with the appropriate coolant mixture (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE).

WARNING: USE EXTREME CAUTION WHEN ENGINE IS OPERATING. DO NOT PUT YOUR HANDS NEAR PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHES.

(10) Start engine and inspect for leaks.

RADIATOR FAN

DESCRIPTION

The hydraulic fan (Fig. 7) replaces both the electric fan and the engine driven mechanical fan. The hydraulic cooling fan is integral to the fan shroud and is located between the radiator and the engine.

The power steering pump supplies the hydraulic fluid and pressure to rotate the cooling fan blade, while the electrical portain of the fan is controlled by the electronic control module (ECM).

The hydraulic fan drive (motor) consists of the three major following components:

1 - COOLANT HOSE 2 - WATER PUMP 3 - WATER PUMP BOLTS

Fig. 6 WATER PUMP - TYPICAL

4 - IDLER PULLEY 5 - IDLER PULLEY CAP 6 - COOLANT HOSE

Page 27

7a - 16 ENGINE WG

RADIATOR FAN (Continued)

• Steering flow control valve

• Fan control valve

• Two stage G-rotor hydraulic drive

The hydraulic fan and drive are not serviceable. Any failure of the fan blade, hydraulic fan drive or fan shroud requires replacement of the fan module. The fan blade and hydraulic fan drive are matched and balanced as a system and servicing either separately would disrupt this balance.

For hydraulic fluid routing information refer to (Fig. 8).

CAUTION: Do not attempt to service the hydraulic cooling fan or fan drive separately replace the cooling module as an assembly. Failure to do so may cause severe damage to the hydraulic cooling fan assembly.

HYDRAULIC FAN STRATEGY

The hydraulic radiator cooling fan is controlled by the Electronic Control Module (ECM). A PWM (Pulse Width Modulated) signal from the ECM controls the fan from 0 to 100% of the available fan speed. There are four inputs to the ECM that determine what speed percentage of fan is required by the vehicle. These inputs are:

• Engine Coolant Temperature

• Transmission Oil Temperature

• Battery Temperature

• A/C System Pressure

By monitoring these four parameters, the ECM can determine if cooling airflow is required. If airflow is required, the ECM will slowly ramp up (speed up) the fan speed until the operating parameter(s) are met for the driving condition. Once the temperature or pressure is reduced to within operating parameters, the fan will adjust or hold its speed to maintain the temperature / pressure requirements.

NOTE: If the ECM is not requesting fan on operation, the fan blade will spin between 100 and 500 RPM when the vehicle is at idle. This is due to a controlled minimum oil flow requirement through the fan drive motor.

Fig. 7 HYDRAULIC RADIATOR COOLING FAN AND

FAN DRIVE

1 - POWER STEERING FLUID COOLER 2 - RADIATOR 3 - HIGH PRESSURE LINE FROM STEERING GEAR PUMP TO

HYDRAULIC FAN MOTOR 4 - HYDRAULIC FAN MOTOR 5 - HIGH PRESSURE LINE FROM HYDRAULIC FAN MOTOR TO

STEERING GEAR 6 - FAN SHROUD

OPERATION

The hydraulic radiator cooling fan replaces both the electric fan and the engine driven mechanical fan. The use of this hydraulic fan provides heavy trailer tow capability while at the same time reducing unnecessary power drain on both the engine and the vehicles electrical system.

ACTIVATING THE HYDRAULIC FAN WITH THE DRBIIIT

Under the Engine Systems test heading, there is a subheading. “Hydraulic fan solenoid test”, that has the selections, on /off. Activating the fan with the DRBIIIt will run the fan at 100% duty cycle, which will help troubleshoot any system problems, and also help with the deaeration procedure.

NOTE: Engine must be running to activate the fan with the DRBIIIT.

RADIATOR COOLING FAN HYDRAULIC FLUID PATH

Hydraulic fluid is pumped from the power steering pump, though a high pressure delivery line, to the fan drive motor. As fluid is diverted through the G-rotors, rotational motion moves fluid from the high-pressure (inlet) side of the motor to the lowpressure (outlet) side. Fluid exiting the drive motor is divided into two paths. Path one continues through a high pressure delivery line to the steering gear, and path two sends fluid back to the power steering pump through a low pressure line. Fluid exits the steering gear under low pressure and travels through a low pressure line to the power steering fluid cooler before being returned back the power steering fluid reservoir (Fig. 7).

Page 28

WG ENGINE 7a - 17

RADIATOR FAN (Continued)

Fig. 8 HYDRAULIC FAN FLUID FLOW CIRCUIT

1 - POWER STEERING RESERVOIR 2 - POWER STEERING PUMP 3 - HYDRAULIC FAN DRIVE ASSEMBLY 4 - FAN BLADE

NOTE: There is a steering flow control valve located in the fan drive motor. Because of the design of the valve, steering assist can not be effected by the radiator cooling fan even during fan drive failure.

REMOVAL

(1) Raise vehicle on hoist. (2) Drain cooling system.(Refer to 7 - COOLING -

STANDARD PROCEDURE)

NOTE: The hydraulic fan drive is driven by the power steering pump. When removing lines or hoses from fan drive assembly use a drain pan to catch any power steering fluid that may exit the fan drive or the lines and hoses.

NOTE: When ever the high pressure line fittings are removed from the hydraulic fan drive the O-rings must be replaced.

5 - HYDRAULIC FAN CONTROL SOLENOID 6 - POWER STEERING OIL COOLER 7 - STEERING GEAR

(3) Disconnect two high pressure lines at hydraulic fan drive (Fig. 9). Remove and discard o-rings from line fittings.

(4) Disconnect low pressure return hose at hydraulic fan drive (Fig. 9).

NOTE: The lower mounting bolts can only be accessed from under vehicle.

(5) Remove two lower mounting bolts from the shroud (Fig. 11).

(6) Lower vehicle.

(7) Disconnect the electrical connector for the fan control solenoid.

(8) Disconnect the radiator upper hose at the radiator and position out of the way.

(9) Disconnect the power steering gear outlet hose and fluid return hose at the cooler (Fig. 10).

(10) Remove two upper mounting bolts from the shroud (Fig. 11).

(11) Remove the shroud and fan drive from vehicle.

Page 29

7a - 18 ENGINE WG

RADIATOR FAN (Continued)

Fig. 9 HYDRAULIC LINES/HOSES AND ELECTRICAL

CONNECTOR

1 - LOW PRESSURE RETURN HOSE 2 - HIGH PRESSURE LINE (OUTLET) 3 - HIGH PRESSURE LINE (INLET) 4 - HYDRAULIC FAN DRIVE

Fig. 11 FAN SHROUD MOUNTING BOLT LOCATIONS

1 - FAN SHROUD UPPER MOUNTING BOLT LOCATIONS 2 - FAN SHROUD LOWER MOUNTING BOLT LOCATIONS

INSTALLATION

CAUTION: There is an external ground wire connected to the hydraulic fan drive located at the electrical connector on the fan assembly. This ground MUST remain connected at all times. Failure to ensure ground before engine is operating can cause severe damage to the ECM.

(1) Position fan drive and shroud in vehicle.

(2) Install fan shroud upper mounting bolts. Do not tighten at this time.

(3) Install radiator upper hose onto radiator.

(4) Connect power steering cooler hoses.

(5) Raise vehicle on hoist.

(6) Install fan shroud lower mounting bolts. Tighten to 6 N·m (50 in. lbs.).

NOTE: When ever the high pressure line fittings are removed from the hydraulic fan drive the o-rings located on the fittings must be replaced.

Fig. 10 POWER STEERING GEAR OUTLET AND

RETURN HOSES

1 - POWER STEERING COOLER RETURN HOSE 2 - POWER STEERING COOLER SUPPLY HOSE

(7) Lubricate the o-rings on the fittings with power steering fluid then connect inlet and outlet high pressure lines to fan drive (Fig. 12). Tighten inlet line to 49 N·m (36 ft. lbs.) tighten outlet line to 29 N·m (21.5 ft. lbs.).

(8) Connect low pressure return hose to fan drive (Fig. 12).

(9) Lower vehicle.

Page 30

WG ENGINE 7a - 19

RADIATOR FAN (Continued)

RADIATOR PRESSURE CAP

DESCRIPTION

all vehicle are equipped with a pressure cap (Fig.

13). This cap releases pressure at some point within a range of 124-to-145 kPa (18-to-21 psi). The pressure relief point (in pounds) is engraved on top of the cap

The cooling system will operate at pressures slightly above atmospheric pressure. This results in a higher coolant boiling point allowing increased radiator cooling capacity. The cap contains a springloaded pressure relief valve. This valve opens when system pressure reaches the release range of 124-to145 kPa (18-to-21 psi).

A rubber gasket seals the radiator filler neck. This is done to maintain vacuum during coolant cool-down and to prevent leakage when system is under pressure.

Fig. 12 HYDRAULIC LINES/HOSES AND

ELECTRICAL CONNECTOR

1 - LOW PRESSURE RETURN HOSE 2 - HIGH PRESSURE LINE (OUTLET) 3 - HIGH PRESSURE LINE (INLET) 4 - HYDRAULIC FAN DRIVE

(10) Install radiator upper hose. (11) Connect electrical connector for hydraulic fan

control solenoid and assure ECM ground to fan

assembly.

(12) Tighten fan shroud upper mounting bolts to 6

N·m (50 in. lbs.).

(13) Refill cooling system (Refer to 7 - COOLING -

STANDARD PROCEDURE).

CAUTION: Do not run engine with power steering fluid below the full mark in the reservoir. Sever damage to the hydraulic cooling fan or the engine can occur.

(14) Refill power steering fluid reservoir and bleed air from steering system (Refer to 19 - STEERING/ PUMP - STANDARD PROCEDURE).

(15) Run engine and check for leaks.

Fig. 13 Radiator Pressure Cap - Typical

1 - FILLER NECK SEAL 2 - VACUUM VENT VALVE 3 - PRESSURE RATING 4 - PRESSURE VALVE

Page 31

7a - 20 ENGINE WG

RADIATOR PRESSURE CAP (Continued)

OPERATION

A vent valve in the center of the cap will remain shut as long as the cooling system is pressurized. As the coolant cools, it contracts and creates a vacuum in cooling system. This causes the vacuum valve to open and coolant in reserve/overflow tank to be drawn through connecting hose into radiator. If the vacuum valve is stuck shut, or overflow hose is kinked, radiator hoses will collapse on cool-down.

DIAGNOSIS AND TESTING - RADIATOR PRESSURE CAP

Remove cap from radiator. Be sure that sealing surfaces are clean. Moisten rubber gasket with water and install the cap on pressure tester (tool 7700 or an equivalent) (Fig. 14).

CAUTION: Radiator pressure testing tools are very sensitive to small air leaks, which will not cause cooling 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 tool. Turn tool upside down and recheck pressure cap to confirm that cap needs replacement.

CLEANING

Clean the radiator pressure cap using a mild soap

and water only.

INSPECTION

Visually inspect the pressure valve gasket on the cap. Replace cap if the gasket is swollen, torn or worn. Inspect the area around radiator filler neck for white deposits that indicate a leaking cap.

RADIATOR

DESCRIPTION

The radiator used with the 2.7L diesel is constructed of a horizontal down-flow aluminum core with plastic side tanks.

Fig. 14 Pressure Testing Radiator Pressure

Cap—Typical

1 - PRESSURE CAP 2 - TYPICAL COOLING SYSTEM PRESSURE TESTER

Operate the tester pump and observe the gauge pointer at its highest point. The cap release pressure should be 124 to 145 kPa (18 to 21 psi). The cap is satisfactory when the pressure holds steady. It is also good if it holds pressure within the 124 to 145 kPa (18 to 21 psi) range for 30 seconds or more. If the pointer drops quickly, replace the cap.

CAUTION: Plastic tanks, while stronger than brass, are subject to damage by impact, such as wrenches.

COOLING MODULE

The cooling module assembly includes the radiatorand hydraulic fan assembly. To replace either one of these components, the entire assembly must be removed from the vehicle and then disassembled. (Refer to 7 - COOLING/ENGINE/RADIATOR REMOVAL)

DIAGNOSIS AND TESTING - RADIATOR FLOW TEST

There is coolant flow through the coolant recovery container before and after the thermostat opens. If engine is cold, idle engine until normal operating temperature is reached. Then feel the upper radiator hose. If the hose is hot, the thermostat is open and water is circulating through the cooling system.

CAUTION: Do not remove the vent valve to insert a temperature gauge thought the opening , coolant will spill out of the system and the engine will not be filled with coolant up to the heads. Major damage could happen if you run the engine in this condition.

Page 32

WG ENGINE 7a - 21

RADIATOR (Continued)

REMOVAL

WARNING: RISK OF INJURY TO SKIN AND EYES FROM SCALDING COOLANT. DO NOT OPEN COOLING SYSTEM UNLESS TEMPERATURE IS BELOW 90°C (194°F). OPEN CAP SLOWLY TO RELEASE PRESSURE. STORE COOLANT IN APPROVED AND APPROPRIATELY MARKED CONTAINER. WEAR PROTECTIVE GLOVES, CLOTHING AND EYE WEAR.

NOTE: Constant tension hose clamps are used on most vehicles. When removing or installing clamps use tools designed for servicing these types of clamps. A number or letter is stamped on the clamp. If replacement is required use only original equipment clamps with a matching letter or number.

NOTE: When removing the radiator, note the location of the rubber radiator-to-body air seals. These seals are used to prevent overheating and must remain in there original positions.

Do Not waste usable coolant. If solution is clean,

drain into a clean container for reuse.

(1) Disconnect negative battery cable.

(2) Drain coolant from radiator (Refer to 7 COOLING/ENGINE/COOLANT - STANDARD PROCEDURE).

NOTE: When ever the high pressure line fittings are removed from the hydraulic fan drive the O-rings

must be replaced.

(3) Disconnect both pressure lines at hydraulic fan drive (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL).

(4) Disconnect low pressure return hose at hydraulic fan drive(Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL).

(5) Disconnect fan electrical connector and set aside.

(6) Remove lower, upper radiator, and coolant pressure container hoses from radiator.

NOTE: The lower portion of the radiator is equipped with two alignment dowel pins that are seated in rubber grommets. These grommets are pressed into the lower cross member and must remain present to prevent radiator tank damage.

Fig. 15 COOLING MODULE

1 - RADIATOR 2 - UPPER RADIATOR HOSE 3 - CHARGE AIR COOLER INLET HOSE 4 - COOLING FAN ELECTRICAL CONNECTOR 5 - CHARGE AIR COOLER OUTLET HOSE 6 - LOWER RADIATOR HOSE 7 - RADIATOR SUPPORT

CLEANING

The radiator and air conditioning fins should be cleaned when an accumulation of bugs, leaves etc. has occurred. Clean radiator fins are necessary for good heat transfer. With the engine cold, apply cold water and compressed air to the back (engine side) of the radiator to flush the radiator and/or A/C condenser of debris.

(7) Remove radiator retaining bolts, and carefully

remove coolant module assembly from vehicle (Fig.

15). (8) Separate coolant fan from radiator.

Page 33

7a - 22 ENGINE WG

RADIATOR (Continued)

INSTALLATION

CAUTION: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEMS HOSES. USE ONLY THE TOOLS THAT ARE DESIGNED FOR THIS TYPE OF SERVICE. A NUMBER OR LETTER IS STAMPED ON THE CLAMP. IF REPLACEMENT IS REQUIRED, USE ONLY AN ORIGINAL EQUIPMENT CLAMP WITH THE MATCHING NUMBER OR LETTER.

NOTE: Care must be taken when installing the radiator not to damage the fins of the radiator or other ancillary components. Note the location and proper installation of the radiator to charge air cooler and radiator to body rubber air seals. These must be installed correctly to prevent engine over heating and provide proper A/C efficiency.

(1) Position the coolant module assembly. (2) Carefully lower the radiator tank alignment

dowels into the rubber grommets in the lower crossmember and secure coolant module.

(3) Connect upper, lower radiator and coolant pres-

sure container hoses then secure.

(4) Connect coolant fan electrical connector and

assure good ECM ground to fan assembly.

NOTE: When ever the pressure line fittings are installed at the hydraulic fan drive, the O-rings must be replaced.

(5) Connect low pressure return hose at hydraulic

fan.

(6) Connect both high pressure hoses at hydraulic

fan.

NOTE: Do Not waste usable coolant. If the solution is clean and the mixture is correct, reuse original coolant.

(7) Refill cooling system with correct mixture with the proper level (Refer to 7 - COOLING/ENGINE/ COOLANT - STANDARD PROCEDURE).

(8) Reconnect negative battery cable.

WARNING: USE EXTREME CAUTION WHEN ENGINE IS OPERATING. DO NOT STAND IN DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHES.

(9) Start engine and inspect for leaks.

Page 34

WG ELECTRONIC CONTROL MODULES 8Ea - 1

ELECTRONIC CONTROL MODULES

TABLE OF CONTENTS

page page

ENGINE CONTROL MODULE

DESCRIPTION ..........................1

OPERATION ............................1

STANDARD PROCEDURE - ECM/SKIM

PROGRAMMING - DIESEL ...............3

REMOVAL .............................3

ENGINE CONTROL MODULE

DESCRIPTION

The ECM is located in the left side of engine compartment attached to the left inner fender behind the battery (Fig. 1).

INSTALLATION ..........................4

TRANSMISSION CONTROL MODULE

DESCRIPTION ..........................4

OPERATION ............................4

STANDARD PROCEDURE - TCM QUICK

LEARN ..............................8

OPERATION

The ECM has been programmed to monitor different circuits of the diesel fuel injection system. This monitoring is called on-board diagnostics. Certain criteria 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 monitored circuit may not be entered into the ECM memory, 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 established 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.

Fig. 1 ENGINE CONTROL MODULE (ECM)

REMOVAL/INSTALL

1 - ECM ELECTRICAL CONNECTORS 2 - ENGINE CONTROL MODULE (ECM) 3 - ECM MOUNTING BRACKET 4 - ECM MOUNTING BRACKET MOUNTING STUDS 5 - MOUNTING BRACKET RETAINING NUTS

ECM OPERATING MODES

As input signals to the ECM change, the ECM adjusts its response to the output devices. For example, 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 determined by engine coolant temperature, atmospheric temperature and battery voltage.

Engine Start-Up Mode

The ECM uses the engine temperature sensor and the crankshaft position sensor (engine speed) inputs to determine fuel injection quantity.

Page 35

8Ea - 2 ELECTRONIC CONTROL MODULES WG

ENGINE CONTROL MODULE (Continued)

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 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 illuminate 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 circuitry. In addition, the ECM monitors the voltage state of some circuits and compares those states with expected values. Other systems are monitored indirectly 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

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 determining the cause of the DTC as well as no trouble code problems. Refer to the appropriate Diesel Powertrain 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 DRBIIIt 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.

INTERMITTENT CODE

A DTC that is not current every time the ECM/ SKIM checks the circuit or function is an intermittent 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 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:

• Visually inspect the related wire harness connectors. Look for broken, bent, pushed out or corroded terminals.

• Visually inspect the related wire harness. Look for chafed, pierced or partially broken wire.

• Refer to hotlines or technical service bulletins that may apply. Refer to the appropriate Diesel Powertrain Diagnostic 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 pullups, drivers and ground circuits). These faults are difficult to detect when a double fault has occurred and only one DTC has set. If the DRBIIIt displays faults for multiple components (i.e.VSS, ECT, Batt Temp, etc.) identify and check the shared circuits for possible problems before continuing (i.e. sensor grounds or 5-volt supply circuits). Refer to the appropriate wiring diagrams to identify shared circuits. Refer to the appropriate Diesel Powertrain Diagnostic Manual for more information.

Page 36

WG ELECTRONIC CONTROL MODULES 8Ea - 3

ENGINE CONTROL MODULE (Continued)

STANDARD PROCEDURE - ECM/SKIM PROGRAMMING - DIESEL

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 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.

ECM/SKIM PROGRAMMING

When a ECM and the SKIM are replaced at the

same time perform the following steps in order:

(1) Program the new ECM (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 IIIt and

turn the ignition on.

(2) Select Engine from the main menu. The DRB IIIt will require the VIN to be entered before continuing.

(3) Select ENTER to update the VIN. The DRB IIIt will display the updated VIN.

(4) If the engine is equipped with air conditioning, the ECM A/C function must be enabled. Enable the ECM A/C function as follows:

• Using the DRB IIIt select ENGINE, MISCEL-

LANEOUS, then ENABLE/DISABLE A/C

• Push 1 to enable A/C. DRB IIIt screen should

display A/C Activated.

PROGRAMMING THE SKIM

(1) Turn the ignition switch on (transmission in park/neutral).

(2) Use the DRB IIIt and select THEFT ALARM, SKIM then MISCELLANEOUS.

(3) Select ECM REPLACED (DIESEL 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 ECM 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 IIIt 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 SKIM. 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 IIIt will display one of the following messages:

Programming Not Attempted - The DRB IIIt attempts to read the programmed key status and there are no keys programmed into SKIM memory.

Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKIM is unable to program key due to one of the following:

• faulty ignition key transponder

• 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 IIIt, erase all ignition keys by selecting MISCELLANEOUS and ERASE ALL CURRENT IGN. KEYS.

(7) Program all ignition keys.

Learned Key In Ignition - Ignition key transponder ID is currently programmed in 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 vehicle (Fig. 2).

(5) Separate ECM from bracket.

Page 37

8Ea - 4 ELECTRONIC CONTROL MODULES WG

ENGINE CONTROL MODULE (Continued)

hydraulic fluid within the transmission, by moving a sequence of four valves to make a shift occur.

The W5J400 electronic transmission has a fully adaptive control system. The system performs its functions based on continuous real-time sensor feedback information. In addition the TCM receives information from the PCM/ECM (engine management) and ABS (chassis systems) controllers over the CAN C bus. The CAN C bus is a high-speed communication bus that allows real time control capability between various controllers. Most messages are sent every 20 milliseconds. This means critical information can be shared between the transmission, engine, and ABS controllers. The CAN C bus is a two wire bus with a CAN C Bus (+) circuit and a CAN C Bus (-) circuit. These circuits are twisted pairs in the harness to reduce the potential of radio and noise interference.

The transmission control system automatically adapts to changes in engine performance, vehicle speed, and transmission temperature variations to provide consistent shift quality. The control system ensures that clutch operation during up-shifting and downshifting is more responsive without increased harshness. The TCM activates the solenoid valves

Fig. 2 ENGINE CONTROL MODULE (ECM)

REMOVAL/INSTALL

1 - ECM ELECTRICAL CONNECTORS 2 - ENGINE CONTROL MODULE (ECM) 3 - ECM MOUNTING BRACKET 4 - ECM MOUNTING BRACKET MOUNTING STUDS 5 - MOUNTING BRACKET RETAINING NUTS

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 ECM electrical connectors (Fig. 2). (5) Connect negative battery cable.

TRANSMISSION CONTROL MODULE

DESCRIPTION

The electronic control system consists of various components providing inputs to the TCM. The TCM monitors transmission sensors, shifter assembly switches, and bus messages to determine transmission shift strategy. After shift strategies are determined, the TCM controls the actuation of transmission solenoids, which controls the routing of

and moves valves in the valve body to achieve the necessary gear changes. The required pressure level is calculated from the load condition, engine speed. Vehicle speed (from ABS module) and transmission oil temperature, matched to the torque to be transmitted. Power for the transmission system is supplied through the shifter mechanism (no transmission control relay). The TCM (Fig. 3) is located in the center console, on the right side of the transmission tunnel.

OPERATION

The transmission control module (TCM) determines the current operating conditions of the vehicle and controls the shifting process for shift comfort and driving situations. It receives this operating data from sensors and broadcast messages from other modules.

The TCM uses inputs from several sensors that are directly hardwired to the controller and it uses several indirect inputs that are used to control shifts. This information is used to actuate the proper solenoids in the valve body to achieve the desired gear. The TCM continuously checks for electrical, mechanical, and some hydraulic problems. When the TCM detects a problem, it stores a Diagnostic Trouble Code (DTC).

The shift lever sensor assembly (SLSA) has sensors that are monitored by the TCM to calculate shift lever position. The reverse light switch, an integral part of the SLSA, controls the reverse light relay con-

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WG ELECTRONIC CONTROL MODULES 8Ea - 5

TRANSMISSION CONTROL MODULE (Continued)

lems. When a problem is sensed, the TCM stores a diagnostic trouble code (DTC). Some of these codes cause the transmission to go into 9Limp-In9 or 9default9 mode. Some faults cause permanent Limp-In and others cause temporary Limp-In. The W5J400 defaults in the current gear position if a DTC is detected, then after a key cycle the transmission will go into Limp-in, which is mechanical 2nd gear. Some DTCs may allow the transmission to resume normal operation (recover) if the detected problem goes away. A permanent Limp-In DTC will recover when the key is cycled, but if the same DTC is detected for three key cycles the system will not recover and the DTC must be cleared from the TCM with the DRBIIIt scan tool.

TCM SIGNALS

The TCM registers one part of the input signals by direct inputs, the other part by CAN C bus. In addition to the direct control of the actuators, the TCM sends various output signals by CAN C bus to other control modules.

Fig. 3 Shifter Assembly and Transmission Control

Module

1 - SHIFTER ASSEMBLY 2 - TRANSMISSION CONTROL MODULE

trol circuit. The Brake/Transmission Shift Interlock (BTSI) solenoid and the park lockout solenoid (also part of the SLSA) are controlled by the TCM.

The PCM and ABS broadcast messages over the

controller area network (CAN C) bus for use by the

TCM. The TCM uses this information, with other inputs, to determine the transmission operating conditions.

The TCM:

• determines the momentary operating conditions

of the vehicle.

• controls all shift processes.

• considers shift comfort and the driving situation.

The TCM controls the solenoid valves for modulating shift pressures and gear changes. Relative to the torque being transmitted, the required pressures are calculated from load conditions, engine rpm, vehicle speed, and ATF temperature.

The following functions are contained in the TCM:

• Shift Program

• Downshift Safety

• Engine Management Intervention

• Torque Converter Lock-Up Clutch.

• Adaptation.

This transmission does not have a TCM relay. Power is supplied to the Shift module and the TCM directly from the ignition.

The TCM continuously checks for electrical problems, mechanical problems, and some hydraulic prob-

Selector Lever Position

A series of 12 Hall-effect switches in the SLSA

inform the TCM of the position of the selector lever.

The TCM monitors the SLSA for all shift lever positions through five position circuits. The SLSA provides a low-current 12-volt signal to the TCM. The TCM compares the on/off signals to programmed combinations to determine the exact position of the shift lever.

ATF Temperature Sensor

The ATF temperature sensor is a PTC thermistor. It measures the temperature of the transmission fluid and is an input signal for the TCM. The temperature of the ATF has an influence on the shift time and resulting shift quality. As the temperature rises, resistance rises. Therefore the probing voltage is decreasing. Because of its registration, the shifting process can be optimized in all temperature ranges.

The ATF temperature sensor is connected in series with the park/neutral contact. The temperature signal is transmitted to the TCM only when the reed contact of the park/neutral contact is closed because the TCM only reads ATF temperature while in a forward gear.

Starter Interlock

The TCM monitors a contact switch wired in series with the transmission temperature sensor to determine PARK and NEUTRAL positions. The contact switch is open in PARK and NEUTRAL. The TCM senses transmission temperature as high (switch supply voltage), confirming switch status as open. The TCM then broadcasts a message over CAN bus

Page 39

8Ea - 6 ELECTRONIC CONTROL MODULES WG

TRANSMISSION CONTROL MODULE (Continued)

to confirm switch status. The PCM receives this information and allows operation of the starter circuit.

N2 and N3 Speed Sensors

The N2 and N3 Input Speed Sensors are two Halleffect speed sensors that are used by the TCM to calculate the transmissions input speed. Since the input speed cannot be measured directly, two of the drive elements are measured. Two input speed sensors were required because both drive elements are not active in all gears.

CAN C Bus Indirect Input Signals

A 2.5-volt bias (operating voltage) is present on the CAN C bus any time the ignition switch is in the RUN position. Both the TCM and the ABS apply this bias. On this vehicle, the CAN C bus is used for module data exchange only. The indirect inputs used on the W5J400 electronic control system are:

• Wheel Speed Sensors.

• Transfer Case Switch Status.

• Brake Switch.

• Engine RPM.

• Engine Temperature.

• Cruise Control Status.

• Gear Limit Request.

• Throttle Position - 0% at idle, 100% at WOT. If

open, TCM assumes idle (0% throttle opening).

• Odometer Mileage

• Maximum Effective Torque.

• Engine in Limp-In Mode/Mileage Where DTC

Was Set.

• Engine Torque Reduction Request.

BRAKE TRANSMISSION SHIFT INTERLOCK (BTSI)

The BTSI solenoid prevents shifting out of the PARK position until the ignition key is in the RUN position and the brake pedal is pressed. The TCM controls the ground while the ignition switch supplies power to the BTSI solenoid. The PCM monitors the brake switch and broadcasts brake switch status messages over the CAN C bus. If the park brake is depressed and there is power (Run/Start) to SLSA, the BTSI solenoid deactivates. The TCM monitors this for the SLSA because the SLSA does not communicate on the CAN C bus.

SHIFT SCHEDULES

The basic shift schedule includes up and downshifts for all five gears. The TCM adapts the shift program according to driving style, accelerator pedal position and deviation of vehicle speed. Influencing factors are:

• Road Conditions.

• Incline, Decline and Altitude.

• Trailer Operation, Loading.

• Engine Coolant Temperature.

• Cruise Control Operation.

• Sporty Driving Style.

• Low and High ATF Temperature.

Upshift

To:

Activated

Solenoid:

Shift

Point (at

35.2% of throttle)

Downshift

From:

Activated

Solenoid:

Shift

Point

1-2 2-3 3-4 4-5

1-2/4-5 2-3 3-4 1-2/4-5

17.8 km/h (11.6 mph)

5-4 4-3 3-2 2-1

1-2/4-5 3-4 2-3 1-2/4-5

55.7 km/h

(34.61

mph)

32.1

km/h

(19.95

mph)

40.5

km/h

(25.17

mph)

67.5

km/h

(41.94

mph)

24.4

km/h

(15.16

mph)

73.8

km/h

(45.86

mph)

15.1 km/h (9.38 mph)

DOWNSHIFT SAFETY

Selector lever downshifts are not performed if inad-

missible high engine rpm is sensed.

ENGINE MANAGEMENT INTERVENTION

By briefly retarding the ignition timing during the shifting process, engine torque is reduced and therefore, shift quality is optimized.

ADAPTATION

To equalize tolerances and wear, an automatic adaptation takes place for:

• Shift Time.

• Clutch Filling Time.

• Clutch Filling Pressure.

• Torque Converter Lock-Up Control.

Adaptation data may be stored permanently and to some extent, can be diagnosed.

Driving Style Adaptation

The shift point is modified in steps based on the information from the inputs. The control module looks at inputs such as:

• vehicle acceleration and deceleration (calculated

by the TCM).

• rate of change as well as the position of the throttle pedal (fuel injection information from the PCM).

Page 40

WG ELECTRONIC CONTROL MODULES 8Ea - 7

TRANSMISSION CONTROL MODULE (Continued)

• lateral acceleration (calculated by the TCM).

• gear change frequency (how often the shift

occurs).

Based on how aggressive the driver is, the TCM moves up the shift so that the present gear is held a little longer before the next upshift. If the driving style is still aggressive, the shift point is modified up to ten steps. If the driving returns to normal, then the shift point modification also returns to the base position.

This adaptation has no memory. The adaptation to driving style is nothing more than a shift point modification meant to assist an aggressive driver. The shift points are adjusted for the moment and return to base position as soon as the inputs are controlled in a more rational manner.

Shift Time Adaptation (Shift Overlap Adaptation, Working Pressure)

Shift time adaptation is the ability of the TCM to electronically alter the time it takes to go from one gear to another. Shift time is defined as the time it takes to disengage one shift member while another is being applied. Shift time adaptation is divided into four categories:

36. Accelerating upshift, which is an upshift under a load. For shift time adaptation for the 1-2 upshift to take place, the transmission must shift from 1st to 2nd in six different engine load ranges vs. transmission output speed ranges.

37. Decelerating upshift, which is an upshift under no load. This shift is a rolling upshift and is accomplished by letting the vehicle roll into the next gear.

38. Accelerating downshift, which is a downshift under load. This shift can be initiated by the throttle, with or without kickdown. The shift selector can also be used.

39. Decelerating downshift, which is accomplished by coasting down. As the speed of the vehicle decreases, the transmission downshifts.

Fill Pressure Adaptation (Apply Pressure Adaptation, Modulating Pressure)

Fill pressure adaptation is the ability of the TCM to modify the pressure used to engage a shift member. The value of this pressure determines how firm the shift will be.

• If too much pressure is used, the shift will be

hard.

• If too little pressure is used, the transmission

may slip.

The pressure adjustment is needed to compensate for the tolerances of the shift pressure solenoid valve. The amount the solenoid valve opens as well as how quickly the valve can move, has an effect on the pressure. The return spring for the shift member provides a resistance that must be overcome by the

pressure in order for shift member to apply. These return springs have slightly different values. This also affects the application pressure and is compensated for by fill pressure adaptation.

Fill Time Adaptation (Engagement Time Adaptation)

Fill time is the time it takes to fill the piston cavity and take up any clearances for a friction element (clutch or brake). Fill time adaptation is the ability of the TCM to modify the time it takes to fill the shift member by applying a preload pressure.

CONTROLLER MODES OF OPERATION

Permanent Limp-In Mode

When the TCM determines there is a non-recoverable condition present that does not allow proper transmission operation, it places the transmission in permanent Limp-In Mode. When the condition occurs the TCM turns off all solenoids as well as the solenoid supply output circuit. If this occurs while the vehicle is moving, the transmission remains in the current gear position until the ignition is turned off or the shifter is placed in the 9P9 position. When the shifter has been placed in 9P,9 the transmission only allows 2nd gear operation. If this occurs while the vehicle is not moving, the transmission only allows operation in 2nd gear.

Temporary Limp-In Mode

This mode is the same as the permanent Limp-In Mode except if the condition is no longer present, the system resumes normal operation.

Under Voltage Limp-In Mode

When the TCM detects that system voltage has dropped below 8.5 volts, it disables voltage-dependant diagnostics and places the transmission in the temporary Limp-In Mode. When the TCM senses that the voltage has risen above 9.0 volts, normal transmission operation is resumed.

Hardware Error Mode

When the TCM detects a major internal error, the transmission is placed in the permanent Limp-In Mode and ceases all communication over the CAN bus. When the TCM has entered this mode normal transmission operation does not resume until all DTCs are cleared from the TCM.

Loss of Drive

If the TCM detects a situation that has resulted or may result in a catastrophic engine or transmission problem, the transmission is placed in the neutral position. Improper Ratio, Input Sensor Overspeed or Engine Overspeed DTCs cause the loss of drive.

Page 41

8Ea - 8 ELECTRONIC CONTROL MODULES WG

TRANSMISSION CONTROL MODULE (Continued)

Controlled Limp-in Mode

When a failure does not require the TCM to shut down the solenoid supply, but the failure is severe enough that the TCM places the transmission into a predefined gear, there are several shift performance concerns. For instance, if the transmission is slipping, the controller tries to place the transmission into 3rd gear and maintain 3rd gear for all forward drive conditions.

STANDARD PROCEDURE - TCM QUICK LEARN

The quick learn procedure requires the use of the DRBIIIt scan tool.

This program allows the electronic transmission system to recalibrate itself. This will provide the proper baseline transmission operation. The quick learn procedure should be performed if any of the following procedures are performed:

• Transmission Assembly Replacement

• Transmission Control Module Replacement

• Solenoid Pack Replacement

• Clutch Plate and/or Seal Replacement

• Valve Body Replacement or Recondition

To perform the Quick Learn Procedure, the follow-

ing conditions must be met:

• The brakes must be applied

• The engine speed must be above 500 rpm

• The throttle angle (TPS) must be less than 3

degrees

• The shift lever position must stay in PARK until

prompted to shift to overdrive

• The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRBt indicates the procedure is complete

• The calculated oil temperature must be above 60° and below 200°

Page 42

WG ENGINE SYSTEMS 8Fa - 1

ENGINE SYSTEMS

TABLE OF CONTENTS

page page

CHARGING ............................... 1 STARTING................................ 8

CHARGING

TABLE OF CONTENTS

page page

CHARGING

DESCRIPTION ..........................1

SPECIFICATIONS

TORQUE - DIESEL .....................1

GENERATOR

DESCRIPTION ..........................2

REMOVAL .............................2

INSTALLATION ..........................2

CHARGING

DESCRIPTION

The charging system used on diesel engines con-

sists of:

• Bosch Generator / field internally controlled

• Ignition switch (Refer to Group 8D, Ignition Sys-

tem for information)

• Battery (Refer to Group 8A, Battery for informa-

tion)

• Wiring harness and connections (Refer to Group

8W, Wiring for information)

SPECIFICATIONS

GENERATOR DECOUPLER PULLEY

DESCRIPTION ..........................3

OPERATION ............................3

DIAGNOSIS AND TESTING - GENERATOR

DECOUPLER ..........................4

REMOVAL .............................4

INSTALLATION ..........................6

The charging system is turned on and off with the ignition switch. The generator is driven by the engine through a serpentine belt and pulley arrangement.

All vehicles are equipped with On-Board Diagnostics (OBD). Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for any failure it detects. See the Powertrain Diagnostic Manual for more information.

TORQUE - DIESEL

DESCRIPTION N-m Ft. Lbs. In. Lbs.

Generator Decoupler 110 81 -

Generator-to-Mounting Bracket Bolts (2) 40 30 -

B+ Generator Output Wire 9 - 75

Page 43

8Fa - 2 CHARGING WG

GENERATOR

DESCRIPTION

The generator is belt-driven by the engine. It is serviced only as a complete assembly. If the generator fails for any reason, the entire assembly must be replaced. On certain generators, a decoupler is used. Refer to Generator Decoupler for additional information.

As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current into the windings of the stator coil. Once the generator begins producing sufficient current, it also provides the current needed to energize the rotor.

The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for rectification. From the diodes, rectified DC current is delivered to the vehicles electrical system through the generator, battery, and ground terminals.

Noise emitting from the generator may be caused by:

• Worn, loose or defective bearings

• Loose or defective drive pulley

• Incorrect, worn or damaged drive belt

• Loose mounting bolts

• Misaligned drive pulley

• Defective stator or diode

• Damaged internal fins

(11) Remove 2 lower generator mounting bolts (Fig. 2). Note lower bolts are slightly shorter than upper bolts.

(12) Lower generator for removal.

Fig. 1 TURBO INTERCOOLER HOSE

1 - INTERCOOLER HOSE 2 - IDLER PULLEY

REMOVAL

WARNING: DISCONNECT NEGATIVE BATTERY

CABLE BEFORE REMOVING GENERATOR B+ OUTPUT WIRE FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN PERSONAL INJURY OR DAMAGE TO VEHICLE ELECTRICAL SYSTEM.

(1) Disconnect negative battery cable.

(2) Remove accessory drive belt from generator pulley by relieving tension on belt tensioner. Refer to Cooling System for procedure.

(3) Remove turbo intercooler hose (Fig. 1).

(4) Loosen (but do not remove) mounting bolt for idler pulley (Fig. 1).

(5) The generator uses 4 horizontally mounted bolts (Fig. 2). Remove 2 upper generator mounting bolts.

(6) Raise vehicle.

(7) Lower oil pan splash shield at right frame rail by disconnecting 2 clips (Fig. 3).

(8) Remove bolt at air conditioning line support bracket (Fig. 4).

(9) Remove B+ output cable nut and cable at rear of generator.

(10) Disconnect generator field wire connector from rear of generator.

Fig. 2 GENERATOR - 2.7L DIESEL

1 - GENERATOR 2 - LOWER MOUNTING BOLTS 3- UPPER MOUNTING BOLTS

INSTALLATION

(1) Raise generator into position from bottom of

vehicle.

Page 44

WG CHARGING 8Fa - 3

GENERATOR (Continued)

(6) Install oil pan splash shield. Press in 2 clips

(Fig. 3).

(7) Lower vehicle. (8) Install 2 upper generator mounting bolts.

Tighten all 4 mounting bolts

(9) Tighten idler pulley bolt. (10) Install turbo intercooler hose (Fig. 1).

(11) Install accessory drive belt by relieving tension on belt tensioner. Refer to Cooling System for procedure.

(12) Connect negative battery cable.

GENERATOR DECOUPLER PULLEY

DESCRIPTION

The generator decoupler is used only with

Fig. 3 OIL PAN SPLASH SHIELD

1 - OIL PAN SPLASH SHIELD 2 - SPLASH SHIELD CLIPS

certain engines. The decoupler is used in place of the standard generator drive pulley (Fig. 5).

Fig. 4 AC LINE AT OIL PAN

1 - OIL PAN (RIGHT/FRONT) 2 - MOUNTING BOLT

(2) Install 2 lower generator mounting bolts finger tight (Fig. 2). Note lower bolts are slightly shorter than upper bolts.

(3) Connect generator field wire connector to rear of generator.

(4) Install B+ output cable nut and cable to rear of generator.

(5) Install bolt at air conditioning line support bracket (Fig. 4).

Fig. 5 GENERATOR DECOUPLER PULLEY

(TYPICAL)

OPERATION

The generator decoupler is used only with

certain engines. The decoupler (Fig. 5). is a one-

way clutch designed to help reduce belt tension fluctuation, vibration, reduce fatigue loads, improve belt life, reduce hubloads on components, and reduce noise. Dry operation is used (no grease or lubricants). The decoupler is not temperature sensitive and also has a low sensitivity to electrical load. The decoupler is a non-serviceable item and is to be replaced as an assembly.

Page 45

8Fa - 4 CHARGING WG

GENERATOR DECOUPLER PULLEY (Continued)

DIAGNOSIS AND TESTING - GENERATOR DECOUPLER

CONDITION POSSIBLE CAUSES CORRECTION

Does not drive generator

(generator not charging)

Internal failure Replace decoupler

Noise coming from

decoupler

Internal failure Replace decoupler

REMOVAL

The generator decoupler is used only with certain engines.

Two different type generator decoupler pulleys are used. One can be identified by the use of machined splines (Fig. 6). The other can be identified by a hex opening (Fig. 7) and will not use splines.

Different special tools are required to service each different decoupler. Refer to following procedure.

Fig. 7 GENERATOR DECOUPLER PULLEY (LITENS)

1 - DECOUPLER (LITENS) 2 - HEX OPENING

Fig. 6 GENERATOR DECOUPLER PULLEY (INA)

1 - GENERATOR 2 - DECOUPLER (INA) 3 - MACHINED SPLINES

INA Decoupler

(1) Disconnect negative battery cable.

(2) Remove generator and accessory drive belt. Refer to Generator Removal.

(3) Position Special Tool #8823 (VM.1048) into

decoupler (Fig. 8).

(4) Determine if end of generator shaft is hex shaped (Fig. 9) or is splined (Fig. 10). If hex is used, insert a 10MM deep socket into tool #8823 (VM.1048) (Fig. 11). If splined, insert a 5/16” 6-point hex driver, or a 10MM 12-point triple square driver into tool #8823 (VM.1048) (Fig. 12).

(5) The generator shaft uses conventional righthand threads to attach decoupler. To break decoupler loose from generator threads, rotate end of tool clockwise (Fig. 11) or, (Fig. 12).

(6) After breaking loose with tool, unthread decoupler by hand from generator.

Page 46

WG CHARGING 8Fa - 5

GENERATOR DECOUPLER PULLEY (Continued)

Fig. 10 END OF GENERATOR SHAFT (SPLINED)

1 - GENERATOR SHAFT 2 - SPLINES

Fig. 8 #8823 (VM.1048) TOOL AND INA DECOUPLER

1 - INA DECOUPLER 2 - TOOL #8823 (VM.1048)

Fig. 9 END OF GENERATOR SHAFT (HEX)

1 - GENERATOR SHAFT 2 - HEX

Fig. 11 DECOUPLER REMOVAL (INA-HEX)

1 - DEEP 10 MM SOCKET 2 - TOOL #8823 (VM.1048)

Page 47

8Fa - 6 CHARGING WG

GENERATOR DECOUPLER PULLEY (Continued)

Fig. 12 DECOUPLER REMOVAL (INA-SPLINED)

1 - DRIVER 2 - TOOL #8823 (VM.1048) 3 - 17 MM WRENCH

Litens Decoupler

(1) Disconnect negative battery cable.

(2) Remove generator and accessory drive belt.

Refer to Generator Removal.

(3) Position Special Tool #8433 (Fig. 13) into

decoupler. Align to hex end of generator shaft.

(4) The generator shaft uses conventional righthand threads to attach decoupler. To break decoupler loose from generator threads, rotate end of tool clockwise (Fig. 14).

(5) After breaking loose with tool, unthread decoupler by hand from generator.

INSTALLATION

INA Decoupler

(1) Thread decoupler pulley onto generator shaft by hand (right-hand threads).

(2) Position Special Tool #8823 (VM.1048) into decoupler (Fig. 8).

Fig. 13 # 8433 TOOL AND LITENS DECOUPLER

Fig. 14 DECOUPLER REMOVAL (LITENS)

(3) Determine if end of generator shaft is hex shaped (Fig. 9) or is splined (Fig. 10). If hex is used, insert a 10MM deep socket into tool #8823 (VM.1048) (Fig. 15). If splined, insert a 5/16” 6-point hex driver, or a 10MM 12-point triple square driver into tool #8823 (VM.1048) (Fig. 16).

Page 48

WG CHARGING 8Fa - 7

GENERATOR DECOUPLER PULLEY (Continued)

(4) Do not use an adjustable, ratcheting “click

type” torque wrench. Most “click type” wrenches will only allow torque to be applied in a clockwise rotation. Use a dial-type or beam-type wrench. Tighten in counter-clockwise

rotation (Fig. 15) or, (Fig. 16). Refer to torque specifications.

(5) Install accessory drive belt, and generator.

Refer to Generator Installation.

(6) Connect negative battery cable.

Fig. 15 DECOUPLER INSTALLATION (INA-HEX)

1 - 10MM DEEP SOCKET 2 - TOOL # 8823 (VM.1048)

Litens Decoupler

(1) Thread decoupler pulley onto generator shaft

by hand (right-hand threads).

(2) Position Special Tool 8433 (Fig. 13) into decou-

pler. Align tool to hex end of generator shaft.

(3) Do not use an adjustable, ratcheting “click

type” torque wrench. Most “click type” wrenches will only allow torque to be applied in a clockwise rotation. Use a dial-type or beam-type wrench. Tighten in counter-clockwise

rotation (Fig. 17). Refer to torque specifications.

(4) Install accessory drive belt, and generator.

Refer to Generator Installation.

(5) Connect negative battery cable.

Fig. 16 DECOUPLER INSTALLATION (INA SPLINED)

1 - DRIVER 2 - TOOL # 8823 (VM.1048)

Fig. 17 DECOUPLER INSTALLATION (Litens)

Page 49

8Fa - 8 STARTING WG

STARTING

TABLE OF CONTENTS

page page

STARTING

SPECIFICATIONS

STARTER MOTOR - DIESEL ..............8

STARTING

SPECIFICATIONS

STARTER MOTOR - DIESEL

Engine Application Diesel Power Rating 2.2 Kilowatt Voltage 12 Volts Number of Fields 4 Number of Poles 4 Number of Brushes 4 Drive Type Planetary Gear Reduction Free Running Test Voltage 11.5 Volts Free Running Test Maximum

Amperage Draw Free Running Test Minimum

Speed Solenoid Closing Maximum

Voltage *Cranking Amperage Draw

test *Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will

increase starter amperage draw.

STARTER MOTOR

REMOVAL - 2.7L DIESEL ..................9

INSTALLATION - 2.7L DIESEL ...............9

Starter and Solenoid

160 Amperes

5500 rpm

7.8 Volts

350 Amperes

Page 50

WG STARTING 8Fa - 9

STARTER MOTOR

REMOVAL - 2.7L DIESEL

(1) Disconnect and isolate negative battery cable. (2) Raise and support vehicle. (3) Remove battery cable mounting nut and cable

eyelet at starter solenoid battery terminal.

(4) Remove 2 starter mounting bolts (Fig. 1).

(5) Partially lower starter to gain access to solenoid wire connector. Do not allow starter motor to hang from the wire harness.

(6) Disconnect solenoid wire at starter: slide red colored tab to unlock; push down on black colored tab while pulling connector from solenoid.

(7) Remove starter from vehicle.

INSTALLATION - 2.7L DIESEL

(1) Position starter motor to transmission.

(2) Install and tighten 2 mounting bolts. Refer to torque specifications.

(3) Connect solenoid wire to starter solenoid. Slide red colored tab to lock connector.

(4) Install battery cable and nut to solenoid stud. Refer to torque specifications.

(5) Lower vehicle.

Fig. 1 STARTER MOTOR - 2.7L DIESEL

1 - STARTER MOTOR 2 - MOUNTING BOLTS (2)

(6) Connect negative battery cable.

Page 51

Page 52

WG IGNITION CONTROL 8Ia - 1

IGNITION CONTROL

TABLE OF CONTENTS

page page

GLOW PLUG

DESCRIPTION ..........................1

OPERATION ............................1

REMOVAL .............................1

INSTALLATION ..........................1

GLOW PLUG

DESCRIPTION

Glow plugs are used to help start a cold or cool engine (Fig. 1). 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.

GLOW PLUG RELAY

DESCRIPTION ..........................2

OPERATION ............................2

DIAGNOSIS AND TESTING - GLOW PLUG

RELAYS ..............................2

ampere. The glow plug is protected this way from overloads.

REMOVAL

CAUTION: Engine temperature must be at least 90°C (194°F) before removing glow plugs. If cylinder head is already removed, warm cylinder head to 90°C (194°F) before removing glow plugs.

(1) Disconnect negative battery cable. (2) Remove engine cover (Refer to 9 - ENGINE -

REMOVAL).

WARNING: NO SPARKS, OPEN FLAMES OR SMOKING. RISK OF POISONING FROM INHALING OR SWALLOWING FUEL. RISK OF INJURY TO SKIN AND EYES EXPOSED TO FUEL. POUR FUELS ONLY INTO SUITABLE AND APPROPRIATELY MARKED CONTAINERS. WEAR PROTECTIVE CLOTHING.

Fig. 1 GLOW PLUG

OPERATION

The glow plugs are used to preheat the combustion chambers in order to achieve the ignition temperature required for the fuel-air mixture.

The glow plug consists of a housing with a female thread and an interference-fit rod. The heating element is integrated in the glow rod. It consists of a heating winding and a control winding connected in series.

When the glow plug system is switched “ON”, a current of about 30 ampere flows to each glow plug. The heating winding heats the glow plug. The control winding increases its resistance as the temperature rises and limits the current to approximately 15-25

NOTE: Press in on fuel line locking tab to release fuel line. Pull back on locking tab to return to lock position.

(3) Remove fuel return flow line to high pressure

pump.

(4) Disconnect glow plug electrical connector (Fig.

2).

WARNING: RISK OF INJURY TO SKIN AND EYES FROM HANDLING HOT OR GLOWING OBJECTS. WEAR PROTECTIVE GLOVES, CLOTHING AND EYE WEAR.

(5) Remove glow plugs and clean glow plug bay

(Fig. 2).

INSTALLATION

(1) Clean glow plug bay and install glow plug.

Tighten glow plugs to 12N·m (106 lbs. in.).

(2) Connect glow plug electrical connector. (Fig. 2).

Page 53

8Ia - 2 IGNITION CONTROL WG

GLOW PLUG (Continued)

GLOW PLUG RELAY

DESCRIPTION

There are two glow plug relays. These relays are located in the Power Distribution Center (PDC) in the engine compartment.

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, during 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.

Fig. 2 GLOW PLUG LOCATION - TYPICAL

1 - GLOW PLUG ELECTRICAL CONNECTOR 2 - GLOW PLUG

NOTE: Press in on fuel line locking tab to release fuel line. Pull back on locking tab to return to lock position.

(3) Install fuel return flow line to high pressure

pump.

(4) Install engine cover (Refer to 9 - ENGINE -

INSTALLATION).

(5) Connect negative battery cable.

WARNING: USE EXTREME CAUTION WHEN ENGINE IS OPERATING. DO NOT STAND IN DIRECT LINE WITH FAN. DO NOT PUT YOUR HANDS NEAR PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHES.

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 relay control circuit is activated when the ignition (key) is switched ON, without the engine running. 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.

Engine

Coolant

Temperature

9Key ON9

-30C 20 SEC. 35 SEC. 200 SEC.

-10C 8 SEC. 23 SEC. 180 SEC. +10C 6 SEC. 21 SEC. 160 SEC. +30C 5 SEC. 20 SEC. 140 SEC. +40C 4 SEC. 19 SEC. 70 SEC. +70C 1 SEC. 16 SEC. 20 SEC.

Wait-To

Start Lamp

9ON9

(Seconds)

Pre-Heat

Cycle

(Glow Plugs On Seconds)

Post-Heat

Cycle

(Seconds)

(6) Start engine and inspect for leaks.

DIAGNOSIS AND TESTING - GLOW PLUG RELAYS

Refer to the appropriate Diesel Powertrain Diagnosis Manual for information on diagnosing the glow plug relays.

Page 54

WG ENGINE 9a - 1

ENGINE

TABLE OF CONTENTS

page page

ENGINE - 2.7L DIESEL

DESCRIPTION

DESCRIPTION ........................2

DESCRIPTION - ENGINE COVER ..........3

STANDARD PROCEDURE

STANDARD PROCEDURE - COMPRESSION

TESTING ENGINE ......................3

INSPECTING ..........................3

STANDARD PROCEDURE - CHECKING OIL

PRESSURE ...........................3

REMOVAL

REMOVAL - 2.7L DIESEL ENGINE ..........4

REMOVAL - ENGINE COVER .............5

INSTALLATION

INSTALLATION - 2.7L DIESEL ENGINE ......5

INSTALLATION - ENGINE COVER ..........6

SPECIFICATIONS - TORQUE

SPECIFICATIONS ......................7

SPECIAL TOOLS ........................11

CYLINDER HEAD

STANDARD PROCEDURE

STANDARD PROCEDURE - CYLINDER

HEAD BOLT INSPECTION ...............16

STANDARD PROCEDURE - MEASURE

CYLINDER HEAD SURFACE .............16

REMOVAL

REMOVAL - CYLINDER HEAD ............17

REMOVAL - CYLINDER HEAD FRONT

COVER .............................17

REMOVAL - CYLINDER HEAD GUIDE RAIL . . 18

INSTALLATION

INSTALLATION - CYLINDER HEAD ........19

INSTALLATION - CYLINDER HEAD FRONT

COVER .............................20

INSTALLATION - CYLINDER HEAD GUIDE

RAIL ...............................20

CYLINDER HEAD COVER(S)

REMOVAL .............................21

INSTALLATION .........................21

VALVE SPRINGS

REMOVAL

REMOVAL - VALVE SPRINGS ............21

REMOVAL - VALVES ...................21

INSTALLATION

INSTALLATION - VALVE SPRINGS ........22

INSTALLATION - VALVES ...............22

CAMSHAFT(S)

STANDARD PROCEDURE - CHECKING

CAMSHAFT POSITION .................23

REMOVAL .............................24

INSTALLATION .........................25

ENGINE BLOCK

STANDARD PROCEDURE

STANDARD PROCEDURE - REPLACING

ENGINE CORE AND OIL GALLERY PLUGS. . 26

STANDARD PROCEDURE - MEASURING

CYLINDER BORES ....................27

CRANKSHAFT

STANDARD PROCEDURE - MEASURE

CRANKSHAFT AND BLOCK JOURNALS ....28

REMOVAL .............................28

INSTALLATION .........................28

CRANKSHAFT OIL SEAL - REAR

REMOVAL .............................29

INSTALLATION .........................29

CRANKSHAFT OIL SEAL - FRONT

REMOVAL .............................30

INSTALLATION .........................31

FLYWHEEL

REMOVAL .............................31

INSTALLATION .........................32

PISTON & CONNECTING ROD

DESCRIPTION .........................32

STANDARD PROCEDURE

STANDARD PROCEDURE - CHECKING AND

REPAIRING CONNECTING RODS .........32

STANDARD PROCEDURE - MEASURING

PISTON PROTRUSION .................34

REMOVAL .............................34

INSTALLATION .........................35

PISTON RINGS

STANDARD PROCEDURE - PISTON RING

FITTING .............................37

VIBRATION DAMPER

REMOVAL .............................39

INSTALLATION .........................39

VACUUM PUMP

DESCRIPTION .........................39

OPERATION ...........................40

REMOVAL .............................40

INSTALLATION .........................40

OIL

REMOVAL - OIL SEPARATOR ..............40

INSTALLATION - OIL SEPARATOR ..........40

OIL JET

DESCRIPTION .........................41

REMOVAL .............................41

INSTALLATION .........................41

Page 55

9a - 2 ENGINE WG

OIL PAN

REMOVAL .............................41

INSTALLATION .........................41

OIL PUMP

REMOVAL

REMOVAL ...........................42

REMOVAL- OIL PUMP CHAIN ............42

INSTALLATION

INSTALLATION .......................42

INSTALLATION - OIL PUMP CHAIN ........43

OIL COOLER & LINES

REMOVAL - OIL COOLER .................45

INSTALLATION - OIL COOLER .............45

INTAKE MANIFOLD

DESCRIPTION - INLET PORT SHUT OFF .....46

OPERATION - INLET PORT SHUT OFF ......46

TIMING CHAIN COVER

REMOVAL .............................46

ENGINE - 2.7L DIESEL

DESCRIPTION

INSTALLATION .........................47

TIMING BELT/CHAIN AND SPROCKETS

REMOVAL

REMOVAL - BOTTOM GUIDE RAIL ........48

REMOVAL - INTERMEDIATE GEAR ........49

REMOVAL - TIMING CHAIN TENSIONING

RAIL ...............................49

REMOVAL - TIMING CHAIN ..............49

INSTALLATION

INSTALLATION - BOTTOM GUIDE RAIL ....51

INSTALLATION - INTERMEDIATE GEAR ....52

INSTALLATION - TIMING CHAIN

TENSIONING RAIL ....................53

ADJUSTMENTS

INSTALLATION - TIMING CHAIN ..........53

TIMING CHAIN TENSIONER

REMOVAL .............................57

INSTALLATION .........................57

DESCRIPTION

This 2.7 Liter five-cylinder Common Rail Diesel Injection (CDI) engine is an in-line overhead valve diesel engine. This engine utilizes a cast iron cylinder block and an aluminum cylinder head. The engine is turbocharged and intercooled. This engine also has for valve per cylinder and dual overhead camshafts (Fig. 1).

DESCRIPTION SPECIFICATION

Engine 2.7L CDI

Engine Description 5 Cylinder In-Line Engine

With 4-Valve Technology

Fuel Injection System Common Rail Diesel

Injection (CDI)

Fuel Diesel

Rated Output 125/4200 kW at RPM

Torque 400/1600-2400 Nm at

RPM

Maximum Speed 4800 RPM

Compression Ratio 19:1

Bore/Stroke 88.0/88.4 mm

Eff. Displacement 2688 cm3

Fig. 1 2.7L DIESEL ENGINE

Page 56

WG ENGINE 9a - 3

ENGINE - 2.7L DIESEL (Continued)

DESCRIPTION - ENGINE COVER

The engine cover is a black plastic cover used to cover the top of the engine (Fig. 2).

sible difference between the individual cylinders is exceeded. Refer to cylinder leak down test.

(10) Remove compression tester and adapter from

cylinder head.

(11) Install glow plugs (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/GLOW PLUG - INSTALLATION).

(12) Install engine cover (Refer to 9 - ENGINE INSTALLATION).

INSPECTING

NOTE: If crankshaft rotates, install retaining lock for crankshaft/ring gear.

(1) Pressurize cylinder with compressed air and read off pressure loss at cylinder leak tester. If excessive pressure loss exists, determine cause. Refer to (DETERMINING PRESSURE LOSS OF CYLINDERS).

NOTE: If the retaining lock is installed, remove it, rotate engine and install lock once again.

(2) Carry out test of other cylinders in the firing order of engine.

Fig. 2 ENGINE COMPARTMENT

1 - COOLANT PRESSURE CONTAINER 2 - ENGINE COVER 3 - RADIATOR

STANDARD PROCEDURE

STANDARD PROCEDURE - COMPRESSION TESTING ENGINE

(1) Warm up engine to operating temperature

(approx. 80 °C ).

(2) Shut off engine. (3) Remove engine cover (Refer to 9 - ENGINE -

REMOVAL).

(4) Remove glow plugs (Refer to 8 - ELECTRICAL/

IGNITION CONTROL/GLOW PLUG - REMOVAL).

(5) Crank engine several times with the starter to

eliminate combustion residues in the cylinders.

(6) Insert compression tester adapter with check valve installed into glow plug hole of cylinder to be tested.

(7) Test compression pressure by cranking engine with starter for at least 8 revolutions.

(8) Carry out test procedure at the remaining cylinders in the same way.

(9) Compare pressure readings obtained with the specified pressures. If the pressure reading is below the minimum compression pressure or if the permis-

STANDARD PROCEDURE - CHECKING OIL PRESSURE

(1) Remove engine cover (Refer to 9 - ENGINE -

REMOVAL).

(2) Remove oil galley plug together with seal at

timing case cover.

(3) Screw oil pressure gauge adaptor fitting

together with seal onto timing case cover.

(4) Connect oil pressure gauge to adaptor fitting. (5) Check oil level, adjust with correct engine oil if

necessary.

(6) Insert temperature of remote thermometer into

oil level indicator tube.

WARNING: USE EXTREME CAUTION WHEN ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH FAN. DO NOT PUT YOUR HANDS NEAR PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHES.

CAUTION: Ensure that fan and accessory drive belt DO NOT damage oil pressure gauge hose.

(7) Start engine and bring to operating tempera-

ture 90°C (194°F).

(8) Record engine oil pressure at idle. (9) Raise engine speed to 3000 rpm and record oil

pressure.

Page 57

9a - 4 ENGINE WG

ENGINE - 2.7L DIESEL (Continued)

(10) At normal operating temperature the oil pressure must not drop below 3 bar (44 psi.). When engine speed is raised, oil pressure must rise with out delay and be no less than 3 bar (44 psi.) at 3000 rpm.

(11) If oil pressure is out of range, determine cause.

REMOVAL

REMOVAL - 2.7L DIESEL ENGINE

WARNING: RISK OF INJURY TO SKIN AND EYES FROM SCALDING WITH HOT COOLANT. RISK OF POISONING FROM SWALLOWING COOLANT. DO NOT OPEN COOLING SYSTEM UNLESS COOLANT TEMPERATURE IS BELOW 90°C (194°F). OPEN CAP SLOWLY TO RELEASE PRESSURE. STORE COOLANT IN SUITABLE AND APPROPRIATELY MARKED CONTAINER. WEAR PROTECTIVE GLOVES, CLOTHES, AND EYE WEAR.

CAUTION: STORE OR DISCARD ALL FULIDS IN SUITABLE AND APPROPRIATELY MARKED CONTAINERS.

(1) Disconnect negative battery cable.

(2) Remove engine cover (Refer to 9 - ENGINE REMOVAL).

(3) Drain cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE).

(4) Evacuate and recover air conditioning system (Refer to 24 - HEATING & AIR CONDITIONING/ PLUMBING - STANDARD PROCEDURE).

(5) Remove front grill and fascia assembly (Refer to 23 - BODY/EXTERIOR/GRILLE - REMOVAL).

(6) Remove headlamp assemblies (Refer to 23 BODY/EXTERIOR/GRILLE FRAME - REMOVAL).

(7) Remove headlamp support.

(8) Remove upper radiator support.

(9) Remove upper radiator hose.

(10) Raise and suitably support vehicle.

(11) Disconnect supply and return lines at viscus fan (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL).

(12) Disconnect lower radiator hose at radiator.

(13) Disconnect transmission cooler hoses at cooler.

(14) Disconnect fan electrical connector.

(15) Lower vehicle.

(16) Disconnect both power steering cooler hoses at cooler.

(17) Remove power steering resivior retaining

bolts.

(18) Lift coolant module from vehicle (Refer to 7 -

COOLING/ENGINE/RADIATOR - REMOVAL).

(19) Remove air cleaner housing assembly. (20) Remove air tube at turbocharger. (21) Remove air conditioning lines from compres-

sor.

(22) Remove junction block bracket from compres-

sor.

(23) Remove turbocharger outlet to charge air

cooler.

(24) Disconnect coolant resivior lines from engine. (25) Disconnect signal line at turbocharger. (26) Disconnect generator B+ at generator.

(27) Disconnect fuel supply and return lines at fuel filter (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL FILTER / WATER SEPARATOR REMOVAL) .

(28) Remove battery (Refer to 8 - ELECTRICAL/ BATTERY SYSTEM/BATTERY - REMOVAL).

(29) Remove battery tray (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/TRAY - REMOVAL).

(30) Disconnect B+ wiring at power distribution center (PDC).

(31) Disconnect pedal position sensor electrical connectors.

(32) Disconnect 3 engine wiring harness connectors.

(33) Remove connector bracket from left sill plate.

(34) Remove exhaust flange retainer at turbocharger.

(35) Disconnect heater hoses.

(36) Raise and suitably support vehicle.

(37) Remove torque converter bolts.

(38) Remove starter (Refer to 8 - ELECTRICAL/ STARTING/STARTER MOTOR - REMOVAL).

(39) Remove transmission bell housing bolts from engine.

(40) Disconnect transmission electrical connectors.

(41) Lower vehicle.

(42) Suitably support transmission.

(43) Connect a suitable engine hoist.

(44) Raise engine approximately 76mm (3 in.).

(45) Remove left engine mount sill plate.

CAUTION: When removing engine care must be taken not to damage crankshaft sensor or other ancellary components.

(46) Remove engine from vehicle.

Page 58

WG ENGINE 9a - 5

ENGINE - 2.7L DIESEL (Continued)

REMOVAL - ENGINE COVER

(1) Firmly grasp front of cover and lift straight up

to release cover from mounting ball studs (Fig. 3).

Fig. 3 ENGINE COVER FRONT MOUNTS

1 - ENGINE COVER 2 - MOUNTING BALL STUDS

(2) Pull cover out of rear mounts and remove from

vehicle (Fig. 4).

INSTALLATION

INSTALLATION - 2.7L DIESEL ENGINE

CAUTION: When installing engine, care must be taken not to damage crankshaft sensor or other ancillary components.

(1) Suitably support transmission. (2) Position engine in bay area approximately

76MM (3 in.) above.

(3) Install left engine mount through bolt into sill

plate, Do Not tighten.

(4) Lower engine until sill plate meets frame rail. (5) Slide engine back toward transmission until

engine meets bell housing.

(6) Raise and suitably support vehicle. (7) Install and tighten transmission bell housing

bolts

(8) Install and tighten transfer case bolts.

Fig. 4 ENGINE COVER REAR MOUNTS

1 - ENGINE COVER 2 - CYLINDER HEAD COVER 3 - REAR MOUNT

(9) Install starter (Refer to 8 - ELECTRICAL/ STARTING/STARTER MOTOR - INSTALLATION).

(10) Connect transmission and transfer case electrical connectors.

(11) Install and tighten torque converter bolts.

(12) Lower vehicle.

(13) Connect heater hoses.

(14) Connect exhaust flange retainer at turbocharger.

(15) Install connector bracket to left sill plate.

(16) Connect engine wiring harnesses.

(17) Connect pedal position sensor electrical harness connectors.

(18) Connect B+ wiring at power distribution center (PDC).

(19) Install battery tray.

(20) Install battery.

(21) Connect fuel supply and return lines.

(22) Connect generator B+ at generator.

(23) Connect signal line at turbocharger.

(24) Connect coolant pressure container lines.

Page 59

9a - 6 ENGINE WG

ENGINE - 2.7L DIESEL (Continued)

(25) Install turbocharger outlet to charge air

cooler.

(26) Install junction block bracket to compressor. (27) Install air conditioning lines to compressor. (28) Install air tube at turbocharger. (29) Install air cleaner housing. (30) Install coolant module (Refer to 7 - COOL-

ING/ENGINE/RADIATOR - INSTALLATION).

(31) Position and install power steering reservoir. (32) Connect both power steering cooler lines to

cooler.

(33) Connect transmission cooler lines at cooler. (34) Connect lower radiator hose to radiator.

(35) Connect supply and return lines at viscous fan (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION).

(36) Install upper radiator hose.

(37) Install upper radiator support (Refer to 7 COOLING/ENGINE/RADIATOR - INSTALLATION)..

(38) Install headlamp support.

(39) Install headlamp assemblies.

(40) Install front grill and fascia assembly.

(41) Fill coolant system with proper mixture to proper level (Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE).

(42) Fill engine oil to proper level. Refer to owners

manual for specifications.

(43) Connect negative battery cable.

(44) Evacuate and recharge air conditioning (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE), (Refer to 24 HEATING & AIR CONDITIONING/PLUMBING STANDARD PROCEDURE).

(45) Bleed air from fuel injection system (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE).

(46) Install engine cover (Refer to 9 - ENGINE INSTALLATION).

(47) Start engine and inspect for leaks.

(48) Check transmission and transfer case oil levels. Refer to owners manual for specifications.

INSTALLATION - ENGINE COVER

(1) Align cover and push into rear mounts (Fig. 4).

(2) Push down front of cover slowly to align mounting ball studs (Fig. 3).

(3) Push down firmly on front of cover to lock cover in place.

Page 60

WG ENGINE 9a - 7

ENGINE - 2.7L DIESEL (Continued)

SPECIFICATIONS - TORQUE SPECIFICATIONS

2.7L DIESEL

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Crankcase Ventilation

Screw-Air Charge Distribution Pipe to Air Charge

Distribution Panel

Cylinder Head

8m-Bolt- Cylinder Head to Timing Case Cover 20 15 -

Bolt-Front Cover to Cylinder Head 14 - 124

12m-Bolt-Cylinder Head to Crankcase (3 stages,

torque, torque angle, torque angle)

Crankcase, Timing Case Cover, End Cover

Bolt-Crankshaft Bearing Cap to Crankcase (2

stages, torque, torque angle) Bolt-End Cover to Crankcase 9 - 80

Bolt-Timing Case Cover to Crankcase 20 15 -

Plug-Coolant Drain to Crankcase 30 22 -

Oil Pan 6m-Bolt-Oil Pan to Crankcase 9 - 80 8m-Bolt-Oil Pan to Crankcase 20 15 -

Bolt-Oil Pan to End Cover 9 - 80

Bolt-Oil Pan to Timing Case Cover 9 - 80

Bolt-Oil Pan to Transmission Bell Housing 40 30 -

Plug-Pil Pan to Oil Drain 47 35 -

Connecting Rod

Bolt-Connecting Rod Cap to Connecting Rod (3

stage, 1&2 torque, 3 torque angle)

Crankshaft

Bolt-Crankshaft Bearing Cap (2 stage, 1 torque, 2

torque angle

Flywheel, Driven Plate, Vibration Damper, Starter Ring Gear

8.8m-Bolt-Central Bolt of Vibration Damper (2 stage, 1 torque, 2 torque angle)

10.9m-Bolt-Central Bolt of Vibration Damper (2 stage, 1 torque, 2 torque angle)

Bolt-Stretch Shank for Flywheel or 2 Mass

Flywheel to Crankshaft (2 stage, 1 torque, 2 torque

angle)

Turbo Charger

Bolt-Oil Feed Line to Cylinder Head 9/22 - 80-194 Bolt-Oil Feed Line to Turbo Charger 30 22 -

Bolt-Turbo Charger Support 30 22 -

Bolt-Turbo Charger Support to Crankcase 20 - 177

Bolt-Oil Outlet Line to Turbo Charger 9 - 80

11 - 97

60, 90°, 90° 44 -

55, 90° 40 -

5,25,90° - 44,221

55,90° 40.5 -

200,90° 147.5 -

325,90° 240 -

45,90° 33

Page 61

9a - 8 ENGINE WG

ENGINE - 2.7L DIESEL (Continued)

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Connection-Flange of Exhaust Manifold to Turbo

Charger

Connection-Turbo Charger to Front Catalytic

Converter

Charge Air Pipe/Charge Air Cooling

Bolt-Charge Air Distribution Pipe 16 - 141

Bolt-Inlet Port Shut Off Positioning Motor to Air

Charge Distribution Pipe

Bolt-Support to Charge Air Distribution Pipe 20 - 177

Bolt-Support to Engine Bracket 40 30 Clamp-Charge Air Pipes/Hoses 3 - 27

Belt Tensioning Device

Bolt-Guide Pully to Coolant Pump 35 26 -

Bolt-Guide Pully to Timimg Case Cover 35 26 -

Bolt-V-Belt Tensioning Device to Tensioning Pully 36 26.5 -

Bolt-V-Belt Tensioning Device to Timing Case

Cover

Exhaust Manifold

Nut-Exhaust Manifold at Cylinder Head 30 22 -

Position Sensor

Nut/Bolt-Camshaft Position Sensor to Cylinder

Head Cover

Nut/Bolt-Crankshaft Position Sensor to Engine

Block

Pre-Glow System

Starter

Alternator

Bolt-Cooler Housing of Generator to Crankcase 20 - 177

Oil Pump

Oil Filter

Oil Cooling System

Cylinder Head to Glow Plug 12 - 106

Bolt-Starter to Crankcase 42 31 Nut-Connection of Circuit 30 14 - 124 Nut-Connection of Circuit 50 6 - 53

Bolt-Generator to Timing Case Cover 20 15 -

Bolt-Generator to Cooler Housing 6 - 53

Nut-B+ Circuit to Generator 13-18 - 115-159 Nut-D+ Circuit to Generator 5 - 44

Nut-Collar to V-Belt Pully 80 59 -

Bolt-Oil Pump to Crankcase 18 - 133

Bolt-Oil Pipe to Crankshaft Bearing Cap 8 - 70

Screw Cap to Oil Filter 25 18.5 -

30 22 -

9-80

30 22 -

11 - 97

8-70

Page 62

WG ENGINE 9a - 9

ENGINE - 2.7L DIESEL (Continued)

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Bolt-Oil-Water Heat Exchanger to Timing Cover

Case

Oil Level Pressure

Bolt-Dip Stick Guide Tube to Cylinder Head 14 - 123

Bolt-Oil Level Sensor to Oil Pan 14 - 123

Coolant Pre- Heater

Coolant Pre-Heater in Engine Block 35 26 -

Engine Cooling General

Bolt-Belt Pully to Coolant Pump 8-35 6 - 26 -

Bolt-Coolant Pump to Timing Case Cover 6m/8m 14/20 10 - 15 -

Bolt-Thremostat Housing to Cylinder Head 9 - 80

Coolant Drain Plug to Crankcase 30 22 Engine Suspension, Engine Mount, Engine Bracket Bolt-Engine Bracket to Crankcase (2 stage, torque,

torque angle)

Bolt-Engine Mount to Engine Bracket 55 40.5 -

Bolt-Front Engine Mount to Front Axle Carrier 35 26 -

Bolt-Rear Engine Cross Member to Body 40 30 -

Bolt-Rear Engine Mount to Rear Engine Cross

Member

Bolt/Nut- Rear Engine Mount to Transmission 40 26 -

Bolt-Shrowd to Engine Bracket 10 - 88.5

Nut-Front Engine Mount to Engine Bracket 65 48 -

Nut-Engine Mount to Vehicle Frame 35 26 -

Fuel Filter

Bolt-Clip to Fuel Filter 8 - 70

Bolt- Fuel Filter to Charge Air Distribution Pipe 14 - 124

Exhaust System

Bolt- Catalytic Converter Bracket to Crankcase 20 - 177

Clamp-Connection Between Front Exhaust Pipe

and Rear Exhaust System

Clip-Front Catalytic Converter to Engine Mount 20 - 177

Nut-Bracket to Tail Pipe 55 40.5 -

Nut-Exhaust Bracket to Threaded Plate of Center

Exhaust Pipe

Support-Exhaust Bracket on Transmission 20 - 177 Refrigerant Compressor Bolt-Refrigerant Compressor to Timing Case Cover 20 - 177

Bolt-Refrigerant Compressor to Bracket 20 - 177

Bolt-Refrigerant Lines to Refrigerant Compressor 20 - 177

Timing Chain, Chain Tensioner

Bolt-Camshaft Sprocket to Exhaust Camshaft 18 - 159

Bolt-Intermediate Gear of High Pressure Pump to

Cylinder Head

15 - 133

20/90° 15 -

35 26 -

55 41 -

20 - 177

40 29.5 -

Page 63

9a - 10 ENGINE WG

ENGINE - 2.7L DIESEL (Continued)

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Timing Chain Tensioner to Timing Case Cover 80 59 -

Camshaft

Bolt-Camshaft Bearing Cap to Cylinder Head 9 - 80

Bolt-Driver to Inlet Camshaft 50 37 -

Common Rail Diesel Injection

Bolt-Bango Bolt of Leak Oil Line to Rail 20 - 177

Bolt-Bracket to High Pressure Pump 9 - 80

Bolt-High Pressure Pump to Cylinder Head 14 - 124

Bolt-Pre-delivery Pump to Top Cover of Cylinder

Head

Bolt-Pressure Control Valve to Rail (2 stage,

torque)

Bolt-Rail to Cylinder Head 14 - 124

Bolt-Shutoff Valve to Cylinder Head 8 - 70

Nut-Pressure Line to Rail/Injector (New,Reused) 22/25 16/18.5 -

Nut-Pressure Line to High Pressure Pump/Rail 22 16 -

Screw-Tensioning Claw to Injector (2 stage, 1

torque, 2 torque angle)

Rail- Pressure Sensor to Rail 22 16 -

Pressure Pipe Connection to Injector 42 31 -

Threaded Rail to Rail 22 16 -

Fuel Cooling System

Bolt-Fuel Cooler to Charge Air Distribution Pipe 14 - 124

Heater Booster, Heater Unit

Bolt- Temperature Controlled Cut Out to Heater

Nut-Threaded Stud to Electronic Heater Booster 18 - 159

Booster control Module

9-80

3/5 - 26/44

7/90° - 62

12 - 106

Page 64

WG ENGINE 9a - 11

ENGINE - 2.7L DIESEL (Continued)

SPECIAL TOOLS

#8927 COMPRESSION TESTER ADAPTER

#8929 CAMSHAFT LOCKING PIN

#8931 TIMING CHAIN RETAINER

#8928 FUEL PRESSURE TESTER

Page 65

9a - 12 ENGINE WG

ENGINE - 2.7L DIESEL (Continued)

#8932 CRANKSHAFT LOCK

#8936 FRONT CRANKSHAFT SEAL INSTALLER

#8937 SLIDE HAMMER

#8938 INJECTOR REMOVER

Page 66

WG ENGINE 9a - 13

ENGINE - 2.7L DIESEL (Continued)

#8940 VIBRATION DAMPER REMOVER

#8942 OIL JET INSTALLER

#8944 REAR MAIN SEAL INSTALLER

#8945 ADAPTER CABLE

Page 67

9a - 14 ENGINE WG

ENGINE - 2.7L DIESEL (Continued)

#8946 VALVE SERVICE TOOLS

#8947 RIVET OPENER

#8948 CHAIN SEPARATOR TOOL

#8949 THRUST PIECE

Page 68

WG ENGINE 9a - 15

ENGINE - 2.7L DIESEL (Continued)

#8950 PRESSING SCREW

#8951 ASSEMBLY LINKS

#8952 ASSEMBLY INSERTS

Page 69

9a - 16 ENGINE WG

CYLINDER HEAD

STANDARD PROCEDURE

STANDARD PROCEDURE - CYLINDER HEAD BOLT INSPECTION

(1) Measure cylinder head bolts between points

shown (Fig. 5).

Cylinder Head

Bolts

Thread

Diameter

Length When

New

Maximum

Length

12 M

102 mm

104 mm

NOTE: The camshaft housing Must Not be machined. Basic bore of the camshaft bearings will be altered.

(7) Machine cylinder head contact surface, if nec-

essary.

(8) Measure cylinder head height (1) at point indicated, record stock removal (Fig. 6) CYLINDER HEAD SPECIFICATIONS .

(9) Measure valve setback at points (2) indicated (Fig. 6) CYLINDER HEAD SPECIFICATIONS .

Fig. 5 MEASURING CYLINDER HEAD BOLTS

(2) If the cylinder head bolt length is greater than the maximum allowable measurement, replace the cylinder head bolts.

STANDARD PROCEDURE - MEASURE CYLINDER HEAD SURFACE

NOTE: Only resurface cylinder head contact surface if porous or damaged. IT IS NOT necessary to rework minor variations in flatness in the longitudinal direction.

(1) Disconnect negative battery cable.

(2) Remove cylinder head (Refer to 9 - ENGINE/ CYLINDER HEAD - REMOVAL).

(3) Remove valves.

(4) Inspect cylinder head contact surface for flatness, porous and damage.

(5) Using a straight edge, measure cylinder head and cylinder block flatness.

(6) Measure cylinder head height at point (1) indicated and retain reading (Fig. 6).

Fig. 6 CYLINDER HEAD MEASURMENTS

NOTE: If measurement is less than dimension “2” no further correct valve clearance compensation is possible; replace valve seat ring or cylinder head if measurement is greater than specification.

CYLINDER HEAD SPECIFICATIONS

Description Specification

Height of Cylinder Head (1), With Out Camshaft Housing

Valve Set Back (2) With New Valves and New Valve Seat Rings

126.85mm to 127.15mm

Exhaust Valve: 1.0mm -

1.4mm

Intake Valve: 1.1mm -

1.5mm

Page 70

WG ENGINE 9a - 17

CYLINDER HEAD (Continued)

REMOVAL

REMOVAL - CYLINDER HEAD

(1) Disconnect negative battery cable.

(2) Raise and support vehicle.

WARNING: RISK OF INJURY TO SKIN AND EYES FROM SCALDING COOLANT. DO NOT OPEN COOLING SYSTEM UNLESS TEMPERATURE IS BELOW 90°C (194°F). OPEN CAP SLOWLY TO RELEASE PRESSURE. STORE COOLANT IN APPROVED CONTAINER ONLY. WEAR PROTECTIVE GLOVES, CLOTHING AND EYE WEAR.

(3) Drain cooling system (Refer to 7 - COOLING/ ENGINE/COOLANT - STANDARD PROCEDURE).

(4) Lower vehicle.

(5) Remove engine cover. (Refer to 9 - ENGINE COVER- REMOVAL).

(6) Remove air cleaner housing.

(7) Remove air intake tube at turbocharger.

(8) Disconnect vacuum hose at turbocharger waste gate solenoid.

(9) Disconnect heater hoses and remove coolant pipe.

WARNING: NO FIRE, OPEN FLAMES OR SMOKING. RISK OF POISONING FROM INHALING AND SWALLOWING FUEL. RISK OF INJURY FROM SKIN AND EYE CONTACT WITH FUEL. POUR FUELS ONLY INTO SUITABLE AND APPROPRIATELY MARKED CONTAINERS. WEAR PROTECTIVE CLOTHING WHEN HANDLING FUEL.

(10) Remove fuel high pressure pipes and injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/ FUEL INJECTOR - REMOVAL).

NOTE: Refer to the appropriate injector servicing procedures for cleaning of the injectors and recesses.

(11) Clean injectors(Refer to 14 - FUEL SYSTEM/ FUEL INJECTION/FUEL INJECTOR - STANDARD PROCEDURE).

(12) Unbolt fuel air bleed at intake manifold and set aside.

(13) Disconnect fuel injector and glow plug wiring harness and set aside.

(14) Remove cylinder head cover (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).

(15) Position piston of cylinder #1 to ignition TDC.

(16) Install retaining lock for crankshaft/starter ring gear.

(17) Remove timing chain tensioner(Refer to 9 ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).

(18) Remove cylinder head front cover(Refer to 9 ENGINE/CYLINDER HEAD - REMOVAL).

(19) Remove top guide rail (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).

(20) Remove camshafts(Refer to 9 - ENGINE/CYLINDER HEAD/CAMSHAFT(S) - REMOVAL).

(21) Remove idler gear (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).

(22) Remove pressure line at high pressure pump.

(23) Remove fuel return flow line between rail and high pressure pump.

(24) Remove high pressure pump (Refer to 14 FUEL SYSTEM/FUEL DELIVERY/FUEL INJECTION PUMP - REMOVAL).

(25) Remove fuel return hose at fuel filter.

(26) Remove charge air distribution pipe (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYSTEM - REMOVAL).

(27) Unbolt oil dip stick tube.

(28) Disconnect viscous heater and set aside.

(29) Disconnect precatalytic converter at turbocharger.

(30) Detach charge air pipe at turbocharger.

(31) Remove oil return flow line at turbocharger.

(32) Remove turbocharger support bracket.

(33) Remove upper timing case to cylinder head bolts.

NOTE: Loosen cylinder head bolts in the reverse order of the tightening sequence.

(34) Remove cylinder head bolts and inspect (Refer to 9 - ENGINE/CYLINDER HEAD - STANDARD PROCEDURE).

(35) Remove cylinder head.

NOTE: Carefully clean all mating surfaces and bolt thread holes. Assure that no oil or grease is present during reassembly.

(36) Clean all mating surfaces and blow out bolt thread holes.

REMOVAL - CYLINDER HEAD FRONT COVER

(1) Disconnect negative battery cable.

(2) Remove engine cover (Refer to 9 - ENGINE REMOVAL).

(3) Partially drain cooling system (Refer to 7 COOLING/ENGINE/COOLANT - STANDARD PROCEDURE).

(4) Disconnect viscous heater pipe and set aside.

Page 71

9a - 18 ENGINE WG

CYLINDER HEAD (Continued)

(5) Disconnect cooling fan power steering hose at

power steering pump and set aside.

(6) Remove cylinder head cover (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).

(7) Remove timing chain tensioner (Refer to 9 ENGINE/VALVE TIMING/TMNG BELT/CHAIN TENSIONER&PULLEY - REMOVAL).

WARNING: NO FIRE, OPEN FLAMES OR SMOKING. SERVICE VEHICLE IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. RISK OF POISONING FROM INHALING AND SWALLOWING FUEL. RISK OF INJURY FROM SKIN AND EYE CONTACT WITH FUEL. POUR FUELS ONLY INTO SUITABLE AND APPROPRIATELY MARKED CONTAINERS. WEAR PROTECTIVE CLOTHING WHEN HANDLING FUEL.

(8) Remove low pressure pump (Refer to 14 FUEL SYSTEM/FUEL DELIVERY/FUEL INJECTION PUMP - REMOVAL).

(9) Remove vacuum pump (Refer to 9 - ENGINE/ ENGINE BLOCK/INTERNAL VACUUM PUMP REMOVAL).

(10) Remove bolts attaching front cover.

NOTE: Lower portion of front cover is sealed with RTV sealant. Carefully tug at front cover until it loosens from cylinder head.

(11) Raise locking pawl of top guide rail and

remove cylinder head front cover (Fig. 7).

NOTE: Dowel pins are use as a guide during assembly and must remain in the proper position to assure a good sealing surface.

REMOVAL - CYLINDER HEAD GUIDE RAIL

(1) Disconnect negative battery cable.

CAUTION: Rotate engine at crankshaft only. DO NOT rotate the engine with the bolt of the camshaft sprocket. DO NOT rotate the engine back.

NOTE: Markings on the camshaft and camshaft bearing cap must be aligned.

1 - TOP GUIDE RAIL 2 - CYLINDER HEAD COVER 3 - LOCKING PAWL 4 - DOWEL PIN 5 - CYLINDER HEAD FRONT COVER

Fig. 7 CYLINDER HEAD FRONT COVER

6 - SEAL 7 - TIMING CHAIN TENSIONER 8 - LOW PRESSURE PUMP 9 - VACUUM PUMP

Page 72

WG ENGINE 9a - 19

CYLINDER HEAD (Continued)

(2) Position piston of number 1 cylinder to ignition TDC.

(3) Remove engine cover. (Refer to 9 - ENGINE/ CYLINDER HEAD/CYLINDER HEAD COVER(S) REMOVAL).

(4) Remove timing chain tensioner (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).

(5) Carefully raise locking pawl of top slide rail and remove front cover at cylinder head (Fig. 7).

(6) Insert a locking pin through 1st camshaft bearing cap into the hole in the inlet camshaft sprocket.

(7) Counter hold the camshaft with an open end wrench to avoid damage and unbolt driver of inlet camshaft sprocket.

(8) Remove top guide rail.

INSTALLATION

INSTALLATION - CYLINDER HEAD

WARNING: NO FIRE, OPEN FLAMES OR SMOKING. SERVICE VEHICLES IN WELL VENTILATED AREAS. RISK OF POISONING FROM INHALING OR SWALLOWING FUEL. RISK OF INJURY FROM SKIN AND EYE CONTACT WITH FUEL. WEAR PROTECTIVE CLOTHING.

NOTE: Thoroughly clean all mating surfaces with appropriate solvents and blow out bolt holes, to assure that no grease or oil is present during reas-

sembly.

NOTE: If piston or connecting rods have been replaced, measure piston projection.

NOTE: Check facing cylinder head contact surface.

(1) Position the cylinder head and gasket properly on engine using the dowel pins as guide.

NOTE: Inspect all cylinder head bolts for defects and stretching before installation (Refer to 9 ENGINE/CYLINDER HEAD - STANDARD PROCEDURE).

CYLINDER HEAD BOLT TORQUE SEQUENCE

The M12 cylinder head bolts must be torqued in 3 stages.

(1) Install M12 cylinder head bolts finger tight.

(2) Torque bolts in numeric order starting with number 1 to 60 N·m (44 lbs.in.) (Fig. 8).

(3) Install M8 timing chain cover to cylinder head

bolts (1A) (Fig. 8). Tighten to 20N·m (177 lbs.in.).

(4) Tighten M12 cylinder head bolts in numeric

order starting with number 1 an additional 90° (Fig.

8). (5) Tighten M12 cylinder head bolts in numeric

order starting with number 1 an additional 90° (Fig.

8).

Fig. 8 CYLINDER HEAD BOLT TORQUE SEQUENCE

(2) Install turbocharger support bracket. Tighten

bolts to 30N·m (22 lbs.ft.).

(3) Install oil return flow line at turbocharger. (4) Attach charge air pipe at turbocharger. (5) Reconnect the precatlytic converter to turbo-

charger. Tighten to 30N·m (22 lbs.ft.).

(6) Install viscous heater. (7) Reconnect oil dip stick tube. Tighten to 14 N·m

(124 lbs. in.).

(8) Install charge air distribution pipe (Refer to 11

- EXHAUST SYSTEM/TURBOCHARGER SYSTEM -

INSTALLATION).

(9) Install fuel return hose at fuel filter. (10) Install high pressure pump (Refer to 14 -

FUEL SYSTEM/FUEL DELIVERY/FUEL INJECTION PUMP - INSTALLATION).

(11) Install fuel return flow line between rail and

high pressure pump.

(12) Install pressure line at high pressure pump. (13) Install idler gear (Refer to 9 - ENGINE/

VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION).

(14) Install camshafts (Refer to 9 - ENGINE/CYL-

INDER HEAD/CAMSHAFT(S) - INSTALLATION).

(15) Install top guide rail (Refer to 9 - ENGINE/

VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION).

(16) Install front cover at cylinder head (Refer to 9

- ENGINE/CYLINDER HEAD - INSTALLATION). (17) Install timing chain tensioner with new gas-

ket. (Refer to 9 - ENGINE/VALVE TIMING/TIMING

Page 73

9a - 20 ENGINE WG

CYLINDER HEAD (Continued)

BELT/CHAIN AND SPROCKETS - INSTALLATION) Tighten to 80N·m (59 lbs.ft.).

(18) Remove retaining lock for crankshaft/starter

ring gear.

(19) Install cylinder head cover (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).

(20) Install and properly route fuel injector and glow plug wiring harness, making appropriate connections.

(21) Install fuel high pressure pipes and injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/ FUEL INJECTOR - INSTALLATION).

(22) Secure fuel air bleed at intake manifold.

(23) Connect vacuum hose at turbocharger waste gate solenoid.

(24) Install air intake tube at turbocharger (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYSTEM - INSTALLATION).

(25) Install air cleaner housing.

(26) Install engine cover (Refer to 9 - ENGINE INSTALLATION).

NOTE: DO NOT pressure test cooling system until engine has reached operating temperature.

(27) Refill cooling system with proper coolant mixture to proper level (Refer to 7 - COOLING/ENGINE/ COOLANT - STANDARD PROCEDURE).

(28) Connect negative battery cable.

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 CLOTHES.

WARNING: NO FIRE, OPEN FLAMES OR SMOKING. REMOVE SOURCES OF IGNITION FROM THE AREA. WEAR PROTECTIVE CLOTHING WHEN HANDLING FUEL. RISK OF POISONING FROM INHALING AND SWALLOWING FUEL. RISK OF INJURY FROM SKIN AND EYE CONTACT WITH FUEL. POUR FUELS ONLY INTO SUITABLE AND APPROPRIATELY MARKED CONTAINERS.

(4) Instal low pressure pump (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL INJECTION PUMP - INSTALLATION).

(5) Install vacuum pump (Refer to 9 - ENGINE/ ENGINE BLOCK/INTERNAL VACUUM PUMP INSTALLATION).

NOTE: Timing chain tensioner must be installed with a new gasket.

(6) Install timing chain tensioner (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION).

(7) Connect power steering hose.

(8) Connect viscous heater pipe.

(9) Refill cooling system with proper mixture to proper level (Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE).

(10) Connect negative battery cable.

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 CLOTHES.

(11) Start the engine and inspect for leaks.

(29) Start engine and inspect for leaks.

INSTALLATION - CYLINDER HEAD FRONT COVER

NOTE: Thoroughly clean all mating surfaces with appropriate solvents to assure that no grease or oil is present during reassembly.

NOTE: Dowel pins are used as a guide during assembly and must remain in the proper position to assure a good sealing surface.

(1) Apply sealant to lower portion and position cyl-

inder head front cover.

(2) Raise locking pawl of top guide rail and guide

front cover onto guide pins.

(3) Install bolts attaching front cover (Fig. 7)

Tighten bolts to 14N·m (124 lbs. in.).

INSTALLATION - CYLINDER HEAD GUIDE RAIL

(1) Carefully position the top guide rail onto the guide pins.

(2) Counter hold the camshaft with an open end wrench and install driver of inlet camshaft sprocket. Tight bolt to 50N·m (37 lbs. ft.).

(3) Remove camshaft sprocket locking pin.

(4) Carefully raise locking pawl of top guide rail and install front cover at cylinder head (Fig. 7).

(5) Install timing chain tensioner with new gasket (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION).

(6) Install engine cover (Refer to 9 - ENGINE/ CYLINDER HEAD/CYLINDER HEAD COVER(S) INSTALLATION).

(7) Reconnect negative battery cable.

Page 74

WG ENGINE 9a - 21

CYLINDER HEAD (Continued)

WARNING: US 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 CLOTHES.

(8) Start engine and inspect for leaks.

CYLINDER HEAD COVER(S)

REMOVAL

(1) Disconnect negative battery cable. (2) Detach hose from oil separator. (3) Disconnect fuel injector and glow plug harness

and set aside.

(4) Remove fuel high pressure pipes and injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/ FUEL INJECTOR - REMOVAL).

(5) Remove cylinder head cover retaining bolts and remove cover.

INSTALLATION

(1) Position cylinder head cover with new gasket and install bolts. Tighten bolts to 20 N·m (177 lbs. in.).

(2) Install and properly route fuel injector and glow plug wiring harness, making appropriate connections.

(3) Install injectors and high pressure pipes (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - INSTALLATION).

(4) Attach oil seperator hose.

(5) Connect negative battery cable.

WARNING: USE EXTREME CAUTION WHEN ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH FAN. DO NOT PUT YOUR HANDS NEAR PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHES.

(6) Start engine and inspect for leaks.

VALVE SPRINGS

REMOVAL

REMOVAL - VALVE SPRINGS

(1) Disconnect negative battery cable.

(2) Remove glow plugs (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/GLOW PLUG - REMOVAL).

(3) Remove injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR REMOVAL).

(4) Remove cylinder head cover (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).

(5) Remove timing chain tensioner (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).

(6) Remove front cover at cylinder head (Refer to 9

- ENGINE/CYLINDER HEAD - REMOVAL).

(7) Remove top guide rail (Refer to 9 - ENGINE/ CYLINDER HEAD - REMOVAL).

(8) Remove camshafts (Refer to 9 - ENGINE/CYLINDER HEAD/CAMSHAFT(S) - REMOVAL).

NOTE: The timing chain must be held in up position so as not to jam during procedure.

(9) Position piston of cylinder to be processed to DTC by rotating the crankshaft clockwise.DO NOT

crank engine.DO NOT rotate engine backward.

(10) Install crankshaft lock, special tool #8932.

(11) Seal injector hole with connection piece and retain with orginal tensioning claw.

(12) Connect cylinder leak tester with adaptors and pressurize the cylinder to 5 bar (73 psi.).

WARNING: Valve springs and retainers must be kept in order of the cylinder they were removed.

NOTE: Using tool, screw retaining fork into threaded edge of cylinder head and position thrust piece vertically at top of valve spring retainer.

(13) Compress valve spring.

(14) Remove valve keepers.

(15) Remove top valve spring retainer and valve spring.

(16) Remove valve stem seals.

(17) Remove bottom valve spring retainer.

NOTE: Inspect all cylinder head components for wear or damage.

(18) Repeat procedure for each cylinder as necessary.

REMOVAL - VALVES

(1) Remove cylinder head (Refer to 9 - ENGINE/ CYLINDER HEAD - REMOVAL).

(2) Place insertion plate into the assembly board in direction of arrows on assembly board.

(3) Mount cylinder head onto assembly board with its front side pointing in direction of arrow on assembly board.

(4) Attach valve assembly tool to cylinder head.

Page 75

9a - 22 ENGINE WG

VALVE SPRINGS (Continued)

WARNING: Suitably mark the valve and the position in the cylinder head before removal. Failure to do so will result in improperly seated valves and possible engine damage after reassembly.

NOTE: Using tool, screw retaining fork into threaded edge of cylinder head and position thrust piece vertically at top of valve spring retainer.

(5) Compress valve spring. (6) Remove valve keepers. (7) Remove top valve spring retainer and valve

spring.

(8) Remove valve stem seals. (9) Remove bottom valve spring retainer. (10) Repeat steps 5 through 9 as necessary. (11) Remove cylinder head from assembly board.

WARNING: Valves, springs and retainers must be kept in order of the cylinder they were removed.

(12) Remove valves.

INSTALLATION

INSTALLATION - VALVE SPRINGS

NOTE: Inspect all valve springs and retainers for wear or damage. Replace as necessary.

(1) Position piston of cylinder to be processed to

TDC by rotating the crankshaft clockwise. NO NOT

crank engine or rotate engine counter clockwise.

(2) Connect cylinder leak tester with adaptors and

pressurize the cylinder to 5 bar (73 psi).

(3) Install lower valve spring retainer. (4) Install valve stem seal. (5) Install valve spring. (6) Install valve spring retainer.

NOTE: Using tool, screw retaining fork into threaded edge of cylinder head and position thrust piece vertically at the top of each valve spring retainer.

NOTE: Ensure that the valve keepers are seated properly.

(7) Compress valve and install valve keepers. (8) Repeat procedure for each cylinder as neces-

sary.

(9) Remove special tooling from cylinder head. (10) Position piston of #1 cylinder to ignition TDC.

(11) Install camshafts and check basic position (Refer to 9 - ENGINE/CYLINDER HEAD/CAMSHAFT(S) - INSTALLATION).

(12) Install top guide rail (Refer to 9 - ENGINE/ CYLINDER HEAD - INSTALLATION).

(13) Install front cover at cylinder head (Refer to 9

- ENGINE/CYLINDER HEAD - INSTALLATION).

(14) Install timing chain tensioner with new gasket (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION)

(15) Install cylinder head cover (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).

(16) Install glow plugs (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/GLOW PLUG - INSTALLATION).

WARNING: SERVICE VEHICLES IN A WELL VENTILATED AREA AND AVOID IGNITION SORCES. RISK OF INJURY TO SKIN AND EYES FROM FUEL JET FLOWING OUT.

(17) Install injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR INSTALLATION).

(18) Reconnect negative battery cable.

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.

(19) Start the engine and inspect for leaks.

INSTALLATION - VALVES

WARNING: Valves must be kept in their original positions in cylinder head. Failure to do so will result in engine damage.

NOTE: Inspect all valves, springs and retainers for wear or damage. Replace as necessary.

(1) Install valves in their original position in the cylinder head.

(2) Mount cylinder head onto assembly board with its front side pointing in the direction of arrow on assembly board.

(3) Install lower valve spring retainer.

(4) Install valve stem seal.

(5) Install valve spring.

(6) Install valve spring retainer.

Page 76

WG ENGINE 9a - 23

VALVE SPRINGS (Continued)

NOTE: Using tool, screw retaining fork into threaded edge of cylinder head and position thrust piece vertically at the top of each valve spring retainer.

NOTE: Ensure that the valve collets are seated properly.

(7) Compress valve and install valve keepers. (8) Repeat steps 3 through 7 as necessary. (9) Remove valve assembly from cylinder head. (10) Remove cylinder head from assembly board. (11) Install cylinder head on engine block (Refer to

9 - ENGINE/CYLINDER HEAD - INSTALLATION).

(12) Install glow plugs (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/GLOW PLUG - INSTALLATION).

(13) Connect negative battery cable.

WARNING: US EXTREME CAUTION WHEN THE ENGINE IS IN OPERATION. 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.

(5) Insert the locking pin through first camshaft bearing cap into the hole in the left inlet camshaft sprocket (Fig. 9).

(14) Start engine and check for leaks.

CAMSHAFT(S)

STANDARD PROCEDURE - CHECKING CAMSHAFT POSITION

WARNING: NO FIRE, SPARKS, OR SMOKING. RISK OF POISONING FROM INHALING AND SWALLOWING FUEL AS WELL AS RISK OF INJURY TO EYES AND SKIN FROM CONTACT WITH FUEL. POUR FUEL ONLY INTO SUITABLE AND MARKED CONTAINERS. WEAR PROTECTIVE CLOTHING WHEN HANDLING FUEL.

(1) Remove injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR REMOVAL).

(2) Clean injectors and recesses(Refer to 14 FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - STANDARD PROCEDURE).

(3) Remove cylinder head cover (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).

NOTE: Rotate engine at crankshaft only. DO NOT crank engine at the camshaft and DO NOT rotate the engine backward.

Fig. 9 CHECKING CAMSHAFT POSITION

1 - CAMSHAFT SPROCKET ALIGNMENT DOTS 2 - CAMSHAFT LOCK POSITION 3 - INTAKE CAMSHAFT SPROCKET 4 - CAMSHAFT AND BEARING CAP ALIGNMENT MARKS 5 - CAMSHAFT LOCKING PIN (SPECIAL TOOL #8929) 6 - INTAKE CAMSHAFT SPROCKET

NOTE: The two markings in the inlet camshaft sprockets must be positioned opposite and markings of camshaft and camshaft bearing cap must be aligned. If not, perform basic position of camshafts.

(6) Remove locking pin from camshaft bearing cap

hole.

(4) Position piston of cylinder #1 to ignition TDC.

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9a - 24 ENGINE WG

CAMSHAFT(S) (Continued)

(7) Install cylinder head cover (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).

(8) Install injectors (Refer to 14 - FUEL SYSTEM/ FUEL INJECTION/FUEL INJECTOR - INSTALLATION).

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 NO WEAR LOOSE CLOTHING.

(9) Start the engine and inspect for leaks.

REMOVAL

(1) Disconnect negative battery cable.

(2) Remove engine cover.(Refer to 9 - ENGINE REMOVAL).

WARNING: NO FIRE, OPEN FLAMES OR SMOKING. RISK OF POISONING FROM INHALING OR SWALLOWING FUEL. RISK OF INJURY FROM SKIN AND EYE CONTACT WITH FUEL. WEAR PROTECTIVE CLOTHING. STORE FUEL ONLY IN SUITABLE AND APPROPRIATELY MARKED CONTAINERS.

(3) Remove high pressure lines and injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/ FUEL INJECTOR - REMOVAL).

(4) Remove cylinder head cover (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).

(5) Position piston of cylinder #1 to ignition TDC.

(6) Lock inlet camshaft (Fig. 10).

(7) Remove timing chain tensioner (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).

NOTE: The lower portain of the cylinder head front cover is sealed with RTV sealant. Carefully tug front cover after bolt removal to loosen from cylinder head.

(8) Remove cylinder head front cover (Refer to 9 ENGINE/CYLINDER HEAD - REMOVAL).

(9) Remove top side rail (Refer to 9 - ENGINE/ CYLINDER HEAD - REMOVAL).

CAUTION: For all work in which the crankshaft should not rotate, secure camshaft gear to timing chain.

Fig. 10 CAMSHAFT ALIGNMENT

1 - EXHAUST CAMSHAFT SPROCKET AND CHAIN MARKING 2 - EXHAUST CAMSHAFT SPROCKET BOLTS 3 - EXHAUST CAMSHAFT SPROCKET 4 - CAMSHAFT ALIGNMENT DOTS 5 - INTAKE CAMSHAFT LOCK POSITION 6 - INTAKE CAMSHAFT SPROCKET 7 - INTAKE CAMSHAFT LOCK (SPECIAL TOOL #8929) 8 - INTAKE CAMSHAFT SPROCKET

Page 78

WG ENGINE 9a - 25

CAMSHAFT(S) (Continued)

(10) Mark camshaft sprocket relative to timing chain.

(11) Unbolt camshaft sprocket from exhaust camshaft.

NOTE: Note the position of dowel pin for camshaft sprocket alignment during reassembly.

(12) Remove camshaft sprocket.

CAUTION: Camshaft bearing caps must remain in proper order and position.

(13) Mark and remove camshaft bearing caps.

(14) Remove the inlet and exhaust camshafts (Fig.

11).

INSTALLATION

CAUTION: The camshafts are sensitive to fracturing. Ensure they are installed free of stress.

CAUTION: Pay attention to assignment of camshafts. Camshaft code numbers are visible on the thrust collar of the axial bearing.

CAUTION: Oil bucket tappets and camshaft bearing points. Inspect ease of operation of bucket tappets.

(1) Install inlet and exhaust camshafts.

CAUTION: Install camshafts so that the two holes in camshaft sprockets are positioned opposite and the markings of the camshaft and camshaft bearing cap are aligned.

(2) Align inlet and exhaust camshafts at axial bearing (Refer to 9 - ENGINE/CYLINDER HEAD/ CAMSHAFT(S) - STANDARD PROCEDURE).

(3) Position piston of cylinder #1 to 30° TDC.

Fig. 11 CAMSHAFTS AND HOUSING ASSEMBLY

1 - CYLINDER HEAD BOLTS 2 - EXHAUST CAMSHAFT 3 - INTAKE CAMSHAFT 4 - CAMSHAFT HOUSING 5 - CYLINDER HEAD

NOTE: Pay attention to markings on camshaft bearing caps.

(4) Install camshaft bearing caps in the proper order. Tighten bolts to 9N·m (80 lbs. in.).

CAUTION: Do not rotate engine counter clockwise.

(5) Position the piston of cylinder #1 to ignition TDC.

NOTE: Pay attention to markings on camshaft bearing caps.

(6) Install the bearing caps in reverse order at the same point. Tighten bearing cap bolts evenly in steps each of 1 turn.

NOTE: The piston of cylinder #1 must be positioned at ignition TDC when the inlet camshaft is locked.

(7) Insert locking pin through the first camshaft bearing cap into the whole in the camshaft sprocket.

NOTE: Do Not use old camshaft sprocket bolts.

(8) Fit camshaft sprocket with timing chain fitted on, onto exhaust camshaft paying attention to position of dowel pin. Tighten bolt to 18N·m (159 lbs.in.).

(9) Install timing chain tensioner (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION).

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9a - 26 ENGINE WG

CAMSHAFT(S) (Continued)

(10) Inspect/Set basic position of camshafts (Refer to 9 - ENGINE/CYLINDER HEAD/CAMSHAFT(S) STANDARD PROCEDURE).

(11) Install cylinder head cover (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).

NOTE: Refer to the appropriate injector servicing procedures for cleaning of injectors and recesses.

(12) Clean and install injectors (Refer to 14 FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - STANDARD PROCEDURE), (Refer to 14 FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - INSTALLATION).

(13) Install engine cover (Refer to 9 - ENGINE INSTALLATION).

(14) Reconnect negative battery cable.

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.

(15) Start engine and inspect for leaks.

1 - CYLINDER BLOCK 2 - REMOVE PLUG WITH PLIERS 3 - STRIKE HERE WITH HAMMER 4 - DRIFT PUNCH 5 - CUP PLUG

CAUTION: Do not drive cup plug into the casting as restricted cooling can result and cause serious engine problems.

Fig. 12 Core Hole Plug Removal

ENGINE BLOCK

STANDARD PROCEDURE

STANDARD PROCEDURE - REPLACING ENGINE

CORE AND OIL GALLERY PLUGS

Using a blunt tool such as a drift and a hammer, strike the bottom edge of the cup plug. With the cup plug rotated, grasp firmly with pliers or other suitable tool and remove plug (Fig. 12).

Thoroughly clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer. Lightly coat inside of cup plug hole with Mopart Stud and Bearing Mount. Make certain the new plug is cleaned of all oil or grease. Using proper drive plug, drive plug into hole so that the sharp edge of the plug is at least 0.5 mm (0.020 in.) inside the lead-in chamfer.

It is not necessary to wait for curing of the sealant. The cooling system can be refilled and the vehicle placed in service immediately.

Page 80

WG ENGINE 9a - 27

ENGINE BLOCK (Continued)

STANDARD PROCEDURE - MEASURING CYLINDER BORES

NOTE: This must be done with engine completely disassembled.

(1) Thoroughly clean all cylinder bores with appro-

priate cleaning solvent.

(2) Measure each cylinder at the three measuring

points shown (Fig. 13).

(3) Using the three measurment point, measure cylinder in the longitudinal and in the transverse direction (Fig. 13).

(4) Use the measurment and table below to group cylinder bores:

Standard size 88.0 mm Group code letter A 88.000-88.006 mm Group code letter X 88.006-88.012 mm Group code letter B 88.012-88.018 mm

Wear limit in longitudinal

0.020 mm

in transverse direction

Permissible variation of

0.000-0.014 mm

cylinder shape (when

new)

Fig. 13 MEASURING CYLINDER BORES

1 - MEASURING POINT OF CYLINDER BORE 2 - MEASURING POINT OF CYLINDER BORE 3 - MEASURING POINT OF CYLINDER BORE 1a - UPPER REVERSAL POINT OF #1 PISTON RING

1b - BOTTOM DEAD CENTER OF PISTON 1c - BOTTOM REVERSAL POINT OF OIL SCRAPER RING 1A - LONGITUDINAL DIRECTION 1B - TRANSVERSE PDIRECTION

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9a - 28 ENGINE WG

CRANKSHAFT

STANDARD PROCEDURE - MEASURE CRANKSHAFT AND BLOCK JOURNALS

NOTE: After any bearing damage occurred, remove all debris which is present in the main oil gallery, connecting rod bores, and in the crankshaft and oil galleries. Include removal of the inserting steel ball of the main oil gallery before cleaning.

(1) Remove crankshaft (Refer to 9 - ENGINE/EN-

GINE BLOCK/CRANKSHAFT - REMOVAL).

(2) Clean all engine parts thoroughly.

CAUTION: After bearing has damage has occurred, replace connecting rods which have suffered overheating because of bearing damage. The connecting rod must not have any cross scores and notches.

(3) Inspect connecting rod. If damage is present,

inspect crankshaft, replace as necessary.

(4) Inspect crankcase. (5) Inspect standard size of crankshaft bearing

shells.

(6) Inspect crankshaft bearing cap. (7) Mount crankshaft radially. (8) Inspect crankshaft bearing play.

CAUTION: The crankshaft bearing caps are numbered consecutively, beginning with the first crankshaft bearing cap at the front of the engine. Attention must be paid to the way crankshaft bearing caps fit.

(5) Unbolt crankshaft bearing caps (Fig. 14).

NOTE: Radial mounting of the main bearings of standard size crankshaft is possible by assigning the color-coded bearing shells.

ASSIGN CRANKSHAFT BEARING SHELLS

The oil pan rail of the cylinder block is marked with chisel punches indicating what bearing shell are used.

(9) Assign crankshaft bearing shells.

(10) Mount crankshaft axially.

(11) Inspect crankshaft bearing play.

REMOVAL

(1) Remove engine (Refer to 9 - ENGINE REMOVAL).

(2) Remove timing case cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL)

(3) Remove end cover.(Refer to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - REAR REMOVAL).

(4) Remove pistons (Refer to 9 - ENGINE/ENGINE BLOCK/PISTON & CONNECTING ROD - REMOVAL).

Fig. 14 CRANKSHAFT ASSEMBLY

1 - BEARING HALVES IN ENGINE BLOCK 2 - THRUST WASHERS IN ENGINE BLOCK 3 - CRANKSHAFT 4 - BEARING HALVES IN MAIN BEARING CAPS 5 - MAIN BEARING CAPS 6 - THRUST WASHERS IN MAIN BEARING CAPS 7 - MAIN BEARING BOLTS

(6) Inspect crankshaft bearing caps and bolts for

wear and stretching.

(7) Remove crankshaft.

INSTALLATION

CAUTION: Oil the bearing shells before inserting crankshaft.

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WG ENGINE 9a - 29

CRANKSHAFT (Continued)

CAUTION: Oil grooves in the thrust washers must point toward the thrust collars of the crankshaft.

CAUTION: Thrust washers in the bearing cap each have two retaining lugs as a anti-twist lock.

CAUTION: Oil thread and head contact surfaces of bolts that retain the crankshaft bearing caps; tighten bolts from inside to outside, beginning at the fit bearing. Rotate crankshaft to check clearance.

(1) Install crankshaft.

CAUTION: The crankshaft bearing caps are numbered consecutively, beginning with the first crankshaft bearing cap at the front of the engine. Attention must be paid to the way the crankshaft bearing caps fit.

(2) Install the crankshaft bearing caps.Tighten bolts in two stages. 55N·m (40.5 lbs ft), then 90°.

(3) Install the pistons (Refer to 9 - ENGINE/ENGINE BLOCK/PISTON & CONNECTING ROD INSTALLATION).

(4) Install the end cover (Refer to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - REAR INSTALLATION).

(5) Install the timing case cover (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).

(6) Install the engine (Refer to 9 - ENGINE -

INSTALLATION).

(7) Fill the crankcase with the correct engine oil, to the proper level. Refer to the owners manual for specifications.

(8) Fill the cooling system with the proper coolant, to the proper level (Refer to 7 - COOLING/ENGINE/ COOLANT - STANDARD PROCEDURE).

(9) Connect the negative battery cable.

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 CLOTHES.

(10) Start engine and inspect for leaks.

CRANKSHAFT OIL SEAL REAR

REMOVAL

This must be done with the transmission removed

from the vehicle.

(1) Disconnect the negative battery cable. (2) Raise and support the vehicle. (3) Drain the engine oil.

NOTE: Loosen all of the oil pan bolts to assure that the oil pan gasket is not damaged when removing the rear main oil seal and end cover assembly.

NOTE: Inspect the oil pan gasket for damage. If the oil pan gasket is damaged, remove the oil pan and replace the oil pan gasket.

(4) Loosen the oil pan bolts. (5) Remove the flywheel.

CAUTION: Care must be taken when removing the rear main seal and adaptor assembly. Failure to do so will result in damage to the oil pan gasket.

(6) Remove the rear main seal/adaptor retaining bolts and carefully pry the adaptor from the crankcase at the adaptor shoulders (Fig. 15).

INSTALLATION

NOTE: Thoroughly clean all mating surfaces with the appropriate solvents to assure that no grease or oil is present during reassembly.

NOTE: Carefully position the rear main seal/adaptor evenly onto the assembly sleeve. The rear main oil seal lip MUST NOT roll over the edge of the tool.

(1) Position the rear main oil seal/adaptor with assembly sleeve onto the crankshaft so that the dowel sleeves fit into the guide holes (Fig. 15). Care must be taken so that the oil pan gasket is not damaged.

(2) Install the rear main seal/adaptor to crankcase bolts and tighten to 9·Nm (80 lbs.in) (Fig. 15).

(3) Tighten the M6 oil pan bolts to 9N·m (80 lbs in) and the M8 bolts to 20 N·m (15 lbs ft).

(4) Install the fly wheel and tighten bolts in two stages (Fig. 15). 45N·m (33 lbs. ft.) then 90°.

(5) Install the oil pan drain plug and tighten to 25N·m (18 lbs ft).

(6) Lower the vehicle.

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9a - 30 ENGINE WG

CRANKSHAFT OIL SEAL - REAR (Continued)

Fig. 15 REAR MAIN SEAL/ADAPTER

1 - FLYWHEEL 2 - FLYWHEEL BOLTS 3 - SPECIAL TOOL 8944 4 - REAR CRANKSHAFT OIL SEAL 5 - REAR CRANKSHAFT SEAL ADAPTER

(7) Fill the crankcase with the correct engine oil,

to the proper level. Refer to owners manual for specifications.

(8) Connect the negative battery cable.

WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHES.

(9) Start the engine and inspect for leaks.

CRANKSHAFT OIL SEAL FRONT

REMOVAL

(1) Disconnect the negative battery cable. (2) Remove the accessory drive belt. (3) Install the retaining lock for the crankshaft/

ring gear.

6 - CRANKSHAFT 7 - ALIGNMENT DOWELS 8 - REAR CRANKSHAFT SEAL ADAPTER RETAINING BOLT 9 - OIL PAN TO REAR CRANKSHAFT SEAL ADAPTER RETAINING BOLT

NOTE: If the hub of the belt pulley/vibration damper is tight, use a puller to remove it. Do Not tilt the puller. The groves of the puller MUST mesh fully into the slots of the belt pulley.

NOTE: Inspect the running surface of the belt pulley for wear.

(4) Remove the belt pully/vibration damper.

CAUTION: Care must be taken to prevent severe damage to the crankshaft and mounting whole for the front crankshaft seal.

(5) Using a suitable prying tool, remove the front crankshaft seal from the timing cover (Fig. 16).

Page 84

WG ENGINE 9a - 31

CRANKSHAFT OIL SEAL - FRONT (Continued)

HANDS NEAR THE PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHES.

(7) Start the engine and inspect for leaks.

FLYWHEEL

REMOVAL

(1) Remove transmission (Refer to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC - W5J400 REMOVAL).

NOTE: M6x90 bolts must be used with retaining lock to prevent damage to rear end cover.

(2) Install retaining lock for crankshaft/starter ring gear.

NOTE: Flywheel does not need balancing or should it be interchanged.

(3) Remove flywheel with both inner and outer washers (Fig. 17).

Fig. 16 FRONT SEAL REMOVAL/INSTALLATION

1 - FRONT CRANKSHAFT OIL SEAL 2 - SEAL INSTALLER SPECIAL TOOL #8936 3 - WASHER 4 - RETAINING BOLT

INSTALLATION

NOTE: Thoroughly clean all mating surfaces with the appropriate solvents to assure that no grease or oil is present during reassembly.

NOTE: Carefully position the front crankshaft seal evenly onto the timing cover.

(1) Install the front crankshaft seal.

(2) Install the belt pulley/vibration damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION).

(3) Remove the retaining lock for the crankshaft/ ring gear.

(4) Install the accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS INSTALLATION).

(5) Reconnect the negative battery cable.

(6) Fill the crankcase with the correct engine oil to the proper level.

WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR

Fig. 17 FLYWHEEL ASSEMBLY

1 - SPECIAL TOOL #8932 CRANKSHAFT LOCK 2 - RETAINING BOLTS 3 - ALIGNMENT PIN 4 - WASHER 5 - FLYWHEEL 6 - FLYWHEEL 7 - FLYWHEEL BOLT

Page 85

9a - 32 ENGINE WG

FLYWHEEL (Continued)

INSTALLATION

NOTE: A flex rod torque wrench must not be used in order to avoid angle errors when tightening to degrees.

(1) Align flywheel and inner and outer washers with straight pin. Tighten bolts in two stages. 45N·m (33 lbs. ft.) then 90°.

(2) Remove the retaining lock from the crankshaft/ starter ring gear.

(3) Install clutch.

(4) Install transmission (Refer to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC - W5J400 INSTALLATION).

(5) Connect negative battery cable.

WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS IN OPERATION. 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 CLOTHES.

(6) Start the vehicle.

PISTON & CONNECTING ROD

DESCRIPTION

The pistons are of a free floating design. Oil jets in the engine block lubricate and cool the piston and pin assembly. The connecting rods have a pressed in place wrist pin bushing which is lubricated by the oil

jets (Fig. 18).

STANDARD PROCEDURE

STANDARD PROCEDURE - CHECKING AND REPAIRING CONNECTING RODS

NOTE: Connecting rods with blue discoloration, cross scores or notches must be replaced. Compensate for different weights by milling off the balancing weight.

(1) Inspect connecting rod for discoloring, cross scores and notches.

Fig. 18 PISTON AND CONNECTING ROD ASSEMBLY

1 - PISTON PIN 2 - PISTON 3 - SNAP RING 4 - CONNECTING ROD ALIGNMENT NUMBERS 5 - CONNECTING ROD BOLT 6 - CONNECTING ROD BEARING 7 - CONNECTING ROD 8 - SNAP RING

(2) Bolt connecting rod bearing cap to connecting rod. Tighten connecting rod bearing caps to initial specification (Refer to 9 - ENGINE/ENGINE BLOCK/ PISTON & CONNECTING ROD - INSTALLATION).

NOTE: Connecting rod and bearing cap are marked in sets and attached with two sleeves.

Page 86

WG ENGINE 9a - 33

PISTON & CONNECTING ROD (Continued)

NOTE: If the maximum permissible diameter is exceeded, grind off contact surface of connecting rod bearing cap by a Maximum of 0.02mm.

(3) Using a dial indicator, measure connecting rod

bearing basic bore, repair as necessary (Fig. 19).

NOTE: If excessive wear is present, press in new connecting rod bushings.

(4) Measure connecting rod bushing inner diame-

ter (Fig. 19).

(5) Inspect wristpin bushing. (6) Measure piston pin end play in connecting rod

bushing.

(7) Measure peak to valley height of connecting

rod bushing on inside.

Fig. 19 MEASURING CONNECTING RODS

CONNECTING ROD SPECIFICATIONS

Distance between middle connecting rod bore to connecting rod bushing bore

Width of connecting rod bearing bore at connecting rod bushing bore

Connecting rod bearing shell basic bore

Allowable out-ofroundness and taper of basic bore

Allowable twist of connecting rod bearing bore to connecting rod bushing bore over a length of 100 mm

Allowable variation of axial parallelism of connecting rod bearing bore to connecting rod bushing bore over a length of 100 mm

Allowable difference in weight of complete connecting rod of an engine

Connecting rod inner bushing

Connecting rod outer bushing

Connecting rod basic bore

Piston pin play in connecting rod

Peak-to-Valley height (Rz) of connecting rod bushing on inside

Connecting rod bolt thread

148.970 mm to 149.030

21.940 mm to 22 mm

51.600 mm to 51.614

30.018 to 30.024 mm

32.575 mm to 32.600

32.500 mm to 32.525

.018 mm to .024 mm

.020 mm

.100 mm

.045 mm

M8x1

Page 87

9a - 34 ENGINE WG

PISTON & CONNECTING ROD (Continued)

STANDARD PROCEDURE - MEASURING PISTON PROTRUSION

After replacing the pistons/connecting rods or machining the engine block contact surface, it is then necessary to measure the piston protrusion.

Measure protrusion between piston crown and cylinder head contact surface without the head gasket installed. The measurment must be carried out in the direction of the piston pin in order to eliminate piston rock.

(1) Measure piston protrusion at the two measuring points (arrows) (Fig. 20).

Piston protrusion with new crankcase should be

0.38 - 0.62 mm.

REMOVAL

(1) Disconnect the negative battery cable. (2) Remove the engine (Refer to 9 - ENGINE -

REMOVAL).

(3) Remove the cylinder head (Refer to 9 -

ENGINE/CYLINDER HEAD - REMOVAL).

(4) Remove the oil pan (Refer to 9 - ENGINE/LU-

BRICATION/OIL PAN - REMOVAL).

(5) Push back on the chain tensioner and remove

the oil pump chain from the oil pump.

(6) Remove the oil pump.

NOTE: Mark the connecting rod and connecting rod bearing cap to each other at the inlet side.

(7) Remove the connecting rod bearing cap.

NOTE: Do Not mix up the top and bottom connecting rod bearing shells.

(8) Mark the connecting rod bearing shell and the

connecting rod bearing cap to each other.

NOTE: If the pistons are used, the direction of travel arrows and the marking of the pistons may no longer be visible because of carbon deposits. The carbon deposits on the pistons must be removed.

Fig. 20 MEASURING PISTON PROTRUSION

1 - PISTON PROTRUSION MEASUREMENT

NOTE: If the arrows indicating the driving direction on the piston are no longer visible, they must be marked again.

(9) Remove the connecting rod together with the

piston through the top of the engine.

NOTE: DO NOT mix up the top and bottom connecting rod bearing shells.

(10) Mark the connecting rod bearing shell and

connecting rod to each other.

CAUTION: Care must be taken not to damage the piston.

Page 88

WG ENGINE 9a - 35

PISTON & CONNECTING ROD (Continued)

1 - PISTON PIN CIRCLIP 2 - PISTON PIN 3 - PISTON ASSEMBLY 4 - CONNECTING ROD AND CAP ALIGNMENT MARKS

(11) Remove the piston pin circle clip. (Fig. 21).

(12) Press the piston pin out of the piston and connecting rod bushing. (Fig. 21).

(13) Inspect the connecting rod for wear and damage.

INSTALLATION

(1) Assign piston to the cylinder bore.

(2) Using the appropriate clean engine oil, oil piston pin and connecting rod bushing.

CAUTION: Assemble the piston and connecting rod so that the arrow is pointing in the direction of travel (in the opposite direction of power flow). The marking on the connecting rod is pointing toward the inlet side.

(3) Assemble piston and connecting rod (Fig. 22).

(4) Insert piston pin by hand (Fig. 22).

Fig. 21 PISTON AND CONNECTING ROD ASSEMBLY

5 - CONNECTING ROD CAP 6 - CONNECTING ROD BOLTS 7 - ENGINE BLOCK

CAUTION: Care must be taken not to damage the piston.

(5) Insert circle clip of piston pin into groove on

piston (Fig. 22).

(6) Using the appropriate clean engine oil, clean the cylinder bores, connecting rod bearing journals, connecting rod bearing shells and pistons.

CAUTION: Offset the piston ring gaps by 120°.

(7) Position a ring compressor over piston and rings. Tighten ring compressor (Fig. 23).Ensure that

ring position does not change during this operation.

CAUTION: Rotate the crankshaft sufficiently so that the connecting rod does not touch the connecting rod journal when the piston is pushed onto the cylinder bore.

Page 89

9a - 36 ENGINE WG

PISTON & CONNECTING ROD (Continued)

(8) Install piston with arrow pointing in the direction of travel (in the opposite direction to power flow) (the marking on the connecting rod should be pointing toward the inlet side). (Fig. 23).

(9) Clean and inspect the connecting rod bolts.

CAUTION: Assure that the correct top and bottom connecting rod bearings shells are used in accordance with the markings.

CAUTION: The anti-twist locks of the connecting rod bearing shells must be located in the slots of the connecting rod bearing caps.

(10) Insert connecting rod bearing shell into connecting rod bearing cap.

CAUTION: The markings on the connecting rod and connecting rod cap must be lined up.

(11) Install connecting rod bearing cap. Tighten

Fig. 22 PISTON AND CONNECTING ROD ASSEMBLY

1 - CIRCLE CLIP 2 - PISTON PIN 3 - PISTON ASSEMBLY 4 - CONNECTING ROD ALIGNMENT MARKINGS 5 - CONNECTING ROD BOLTS 6 - CONNECTING ROD CAP 7 - CONNECTING ROD

bolts in 3 stages, 5N·m (44 lbs in), 25N·m (221 lbs in), 90°.

(12) Rotate crankshaft fully and check the clearance.

Fig. 23 PISTON AND CONNECTING ROD INSTALLATION

1 - PISTON RING COMPRESSOR 2 - WOOD HAMMER HANDLE 3 - CONNECTING ROD ALIGNMENT MARKINGS 4 - CONNECTING ROD BOLTS 5 - CONNECTING ROD CAP

6 - CONNECTING ROD 7 - CIRCLE CLIP 8 - PISTON PIN 9 - PISTON ASSEMBLY

Page 90

WG ENGINE 9a - 37

PISTON & CONNECTING ROD (Continued)

(13) Install oil pump (Refer to 9 - ENGINE/LU-

BRICATION/OIL PUMP - INSTALLATION).

(14) Install engine oil pan and oil pan drain plug (Refer to 9 - ENGINE/LUBRICATION/OIL PAN INSTALLATION).

CAUTION: Install a cylinder head gasket of standard thickness or a cylinder head gasket of repair thickness depending on piston projection.

(15) Measure piston projection (Refer to 9 ENGINE/ENGINE BLOCK - STANDARD PROCEDURE).

(16) Install cylinder head (Refer to 9 - ENGINE/ CYLINDER HEAD - INSTALLATION).

(17) Install engine (Refer to 9 - ENGINE INSTALLATION).

(18) Fill the crankcase with correct engine oil, to proper level. Refer to owners manual for specifications.

(19) Fill the cooing system with proper coolant, to the proper level (Refer to 7 - COOLING/ENGINE/ COOLANT - STANDARD PROCEDURE).

(20) Connect negative battery cable.

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 CLOTHES.

(21) Start the engine and inspect for leaks.

PISTON RINGS

STANDARD PROCEDURE - PISTON RING FITTING

(1) Carefully clean the carbon from all ring grooves. Oil drain openings in the oil ring groove and pin boss must be clear. DO NOT remove metal from the grooves or lands. This will change ring-to-groove clearances and will damage the ring-to-land seating.

(2) Be sure the piston ring grooves are free of nicks and burrs.

(3) Measure the ring side clearance with a feeler gauge fitted snugly between the ring land and ring (Fig. 24). Rotate the ring in the groove. It must move freely around circumference of the groove.

Fig. 24 Ring Side Clearance Measurement

1 - FEELER GAUGE

RING SIDE CLEARANCE CHART

ITEM SPECIFICATION

Top Compression Ring 0.012 - 0.016 mm

(0.0047 - 0.0063 in.)

Second Compression

Ring

Oil Control Ring 0.03 - 0.07 mm

0.05 - 0.09 mm

(0.0019 - 0.0035 in.)

(0.0011 - 0.0027 in.)

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9a - 38 ENGINE WG

PISTON RINGS (Continued)

(4) Place ring in the cylinder bore and push down with inverted piston to position near lower end of the ring travel. Measure ring gap with a feeler gauge fitting snugly between ring ends (Fig. 25).

Fig. 26 Compression Ring Installation

1 - COMPRESSION RING 2 - RING EXPANDER RECOMMENDED

Fig. 25 Gap Measurement

1 - FEELER GAUGE

RING GAP MEASUREMENT CHART

ITEM SPECIFICATION

Top Compression Ring 0.229 - 0.610 mm

(0.0090 - 0.0240 in.)

Second Compression

0.483 - 0.965 mm

Ring

(0.0190 - 0.080 in.)

Oil Control Ring 0.254 - 1.500 mm

(0.010 - 0.060 in.)

(5) The oil control rings are symmetrical, and can be installed with either side up. It is not necessary to use a tool to install the upper and lower rails. Insert oil rail spacer first, then side rails.

(6) Using a ring expander, install compression rings with manufactures designation pointing toward piston crown (Fig. 26).

Ring Gap Orientation

• Position the gaps on the piston as shown (Fig.

27).

• Oil spacer - Gap on center line of piston skirt.

• Oil rails - gap 180° apart on centerline of piston

pin bore.

• No. 2 Compression ring - Gap 120° from top oil

rail gap.

• No. 1 Compression ring - Gap 120° from No. 2

compression ring gap.

Fig. 27 Ring Gap Orientation

1 - TOP COMPRESSION RING 2 - BOTTOM COMPRESSION RING 3 - TOP OIL CONTROL RAIL 4 - OIL RAIL SPACER 5 - BOTTOM OIL CONTROL RAIL 6 - IMAGINARY LINE PARALLEL TO PISTON PIN 7 - IMAGINARY LINE THROUGH CENTER OF PISTON SKIRT

Page 92

WG ENGINE 9a - 39

VIBRATION DAMPER

REMOVAL

(1) Disconnect negative battery cable.

(2) Remove accessory drive belt (Refer to 7 COOLING/ACCESSORY DRIVE/DRIVE BELTS REMOVAL).

(3) Install retaining lock for crankshaft/ring gear (Fig. 28).

(4) Remove crankshaft center bolt and washer (Fig. 28).

NOTE: If hub of belt pulley/vibration damper is tight, use puller to remove. DO NOT tilt puller when in use. Grooves of the puller must mesh fully into the slots of the belt pulley.

(5) Remove the belt pulley/vibration damper (Fig.

28).

NOTE: If grooves can be felt in the belt pulley/vibration damper during inspection, the pulley/damper must be replaced.

(6) Inspect hub at belt pulley/vibration damper for

wear grooves.

(7) Replace front crankshaft seal.

INSTALLATION

NOTE: Align parallel key, fix in place with grease. Turn to ensure the slot is aligned with parallel key in crankshaft.

NOTE: Front crankshaft seal must be replaced before installing the belt pulley/vibration damper.

(1) Position the belt pulley/vibration damper.

(2) Install crankshaft center bolt and washer. Tighten bolt in two stages. M8.8 bolt to 200N·m (148 lbs. ft.) then 90°, M10.9 bolt to 325N·m (240 lbs. ft.) then 90°.

NOTE: Inspect accessory drive belt for wear. Replace as necessary.

Fig. 28 VIBRATION DAMPER/CRANKSHAFT PULLEY

1 - SPECIAL TOOL #8932 2 - RETAINING BOLTS 3 - VIBRATION DAMPER/CRANKSHAFT PULLEY 4 - WASHER 5 - CRANKSHAFT BOLT

(3) Install accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).

(4) Reconnect negative battery cable.

WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS IN OPERATION. 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.

(5) Start vehicle and inspect for leaks.

VACUUM PUMP

DESCRIPTION

The vacuum pump is operated by a slotted extension attached to the vacuum pump shaft. The vacuum pump shaft slotted extension fits into, and is driven by, the exhaust camshaft gear.

The vacuum pump is a constant displacement, vane-type pump. Vacuum is generated by vanes mounted in the pump rotor. The rotor is located in the pump housing and is pressed onto the pump shaft.

The vacuum pump rotating components are internally lubricated.

The vacuum pump is not serviceable and must be replaced as a unit. Do not disassemble or attempt to repair the pump.

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9a - 40 ENGINE WG

VACUUM PUMP (Continued)

OPERATION

Vacuum pump output is transmitted to the Heater, Electronic, Vacuum, Air Conditioner (HEVAC) and speed control, systems through a supply hose. The hose is connected to an outlet port on the pump housing and uses an in-line check valve to retain system vacuum when vehicle is not running.

Pump output ranges from a minimum of 8.5 to 25 inches vacuum.

The pump rotor and vanes are rotated by the pump drive gear. The drive gear is operated by the exhaust camshaft gear.

REMOVAL

(1) Disconnect negative battery cable.

(2) Remove engine cover (Refer to 9 - ENGINE REMOVAL).

(3) Partailly drain coolant system (Refer to 7 COOLING/ENGINE/COOLANT - STANDARD PROCEDURE).

(4) Disconnect viscous heater line and set aside.

(5) Disconnect cooling fan, power steering line and set aside.

(6) Remove vacuum line at vacuum pump.

NOTE: Observe position of driver on rear of pump.

(7) Remove vacuum pump and seals (Fig. 29).

(8) Clean all sealing surfaces.

INSTALLATION

(1) Clean all sealing surfaces.

(2) Position driver on rear of pump and install vacuum pump with new seals. Tighten bolts to 14N·m (124 lbs. in.).

(3) Install vacuum line to vacuum pump.

(4) Reconnect cooling fan , power steering hose.

(5) Reconnect viscous heater pipe.

(6) Install engine cover (Refer to 9 - ENGINE INSTALLATION).Tighten screws to 10 N·m (89 lbs. in.).

(7) Connect negative battery cable.

(8) Refill coolant system with correct mixture to proper level (Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE).

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 CLOTHES.

Fig. 29 VACUUM PUMP AND LOW PRESSURE FUEL

PUMP ASSEMBLIES

1 - VACUUM LINE 2 - FUEL OUTLET LINE 3 - FUEL FEED LINE 4 - LOW PRESSURE FUEL PUMP 5 - VACUUM PUMP

OIL

REMOVAL - OIL SEPARATOR

(1) Disconnect breather hose. (2) Remove the separator retaining bolts (3) Twist to remove oil separator from cover.

INSTALLATION - OIL SEPARATOR

(1) Lubricate the oil separator o - ring with clean

engine oil.

(2) Position separator above cover and apply down-

ward pressure to seat.

(3) Install retaining bolts and tighten to 8N·m (70

lbs. in.).

(4) Connect breather hose.

(9) Start the engine and inspect for leaks.

Page 94

WG ENGINE 9a - 41

OIL JET

DESCRIPTION

There are five oil jets installed in the engine block (Fig. 30). These oil jets are used to cool and lubricate the piston assemblies.

Fig. 30 OIL JET LOCATION

1 - ENGINE BLOCK 2 - OIL JET

REMOVAL

The engine must be removed from the vehicle and completely dissassembled to replace the oil jets.

(1) Remove engine from vehicle.

(2) Completely dissassemble engine.

(3) Using an extraction claw and a slide hammer, remove the oil jets from engine block.

INSTALLATION

(1) Install oil jet into special tool #8924.

(2) Align oil jet in location in engine block.

(3) Drive oil jets into block using special tool #8924 until oil jet is fully seated into engine block (Fig. 31).

(4) Reassemble engine.

(5) Install engine into vehicle.

OIL PAN

REMOVAL

(1) Disconnect negative battery cable.

(2) Raise and support vehicle.

(3) Drain engine oil.

Fig. 31 OIL JET INSTALLATION

1 - OIL JET INSTALLER #8942 2 - ENGINE BLOCK 3 - OIL JET

(4) Remove engine cover (Refer to 9 - ENGINE -

REMOVAL).

NOTE: Oil pan bolts are different diameters and lengths and must be installed in their proper position.

(5) Remove oil pan bolts, oil pan and gasket.

INSTALLATION

NOTE: Thoroughly clean all mating surfaces with the appropriate solvents to assure that no grease or oil is present during reassembly.

NOTE: Oil pan bolts are different diameters and lengths. They must be installed in the proper position.

(1) Install the oil pan. Tighten M6 bolts to 9N·m

(80 lbs. in.) and M8 bolts to 20N·m (15 lbs. ft.).

(2) Refill crankcase with the proper engine oil to the proper level. Refer to owners manual for specification.

(3) Reconnect negative battery cable.

WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHES.

(4) Start the engine and inspect for leaks.

Page 95

9a - 42 ENGINE WG

OIL PUMP

REMOVAL

(1) Disconnect negative battery cable. (2) Remove oil pan (Refer to 9 - ENGINE/LUBRI-

CATION/OIL PAN - REMOVAL).

(3) Unbolt oil pump from crankcase. (4) Press chain tensioner off oil pump chain and

remove oil pump (Fig. 32).

Fig. 32 OIL PUMPASSEMBLY

1 - OIL PUMP CHAIN 2 - OIL PUMP CHAIN TENSIONER 3 - O-RING 4 - OIL PUMP

REMOVAL- OIL PUMP CHAIN

(1) Disconnect negative battery cable. (2) Remove oil pan (Refer to 9 - ENGINE/LUBRI-

CATION/OIL PAN - REMOVAL).

(3) Remove oil pump (Refer to 9 - ENGINE/LU-

BRICATION/OIL PUMP - REMOVAL).

(4) Using special tool #8948, position and fit chain seperating tool and thrust spindle onto a link of the oil pump chain (Fig. 33).

(5) Screw the thrust pin in and seperate the oil pump chain link.

(6) Remove pressed - out oil pump chain pin from chain seperation tool.

Fig. 33 OIL PUMP CHAIN LINK REMOVAL

1 - VIBRATION DAMPER/PULLEY 2 - OIL PUMP CHAIN 3 - SPECIAL TOOL #8948

CAUTION: IT IS ESSENTIAL that the installation procedure for the oil pump chain is followed exactly. Failure to do so will result in severe engine damage.

INSTALLATION

NOTE: Clean strainer of oil pump. If oil pump is dry, fill with appropriate engine oil.

(1) Position oil pump and install oil pump chain. (2) Install oil pump and seal.Tighten bolts to

18N·m (159 lbs. in.).

(3) Install oil pan (Refer to 9 - ENGINE/LUBRI-

CATION/OIL PAN - INSTALLATION).

(4) Fill crankcase to proper level with correct

engine oil. Refer to owners manual for specification.

(5) Reconnect negative battery cable.

WARNING: USE EXTREME CAUTION WHEN ENGINE IS OPERATING. DO NOT PUT YOUR HANDS NEAR PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHES.

(6) Start engine and inspect for leaks.

Page 96

WG ENGINE 9a - 43

OIL PUMP (Continued)

INSTALLATION - OIL PUMP CHAIN

CAUTION: IT IS ESSENTIAL that the installation procedure is followed exactly. Failure to do so will result in severe engine damage.

(1) Connect old oil pump chain and new chain with temporary link, outer plate and locking element (Fig.

34).

Fig. 34 INSTALLING OIL PUMP CHAIN TEMPORARY

1 - VIBRATION DAMPER/CRANKSHAFT PULLEY 2 - OLD OIL PUMP CHAIN 3 - NEW OIL PUMP CHAIN 4 - TEMPORARY LINK

LINK

(2) Slowly rotate crankshaft in a clockwise direction until it is possible to connect the ends of the new and old oil pump chains.

(3) Remove assembly locking element, outer plate and assembly link (Fig. 35).

CAUTION: Insert new riveted link from the rear.

(4) Connect ends of new oil pump chain with new riveted link (Fig. 36).

Fig. 35 REMOVING OIL PUMP CHAIN TEMPORARY

LINK

1 - NEW OIL PUMP CHAIN 2 - OLD OIL PUMP CHAIN 3 - TEMPORARY LINK

NOTE: When assembling riveting tool, one piece is secured by a screw and the other can move loosely on the thrust spindle.

Fig. 36 INSTALLING NEW RIVETED LINK

1 - NEW RIVETED LINK 2 - OIL PUMP CHAIN

Page 97

9a - 44 ENGINE WG

OIL PUMP (Continued)

(5) Assemble riveting tool by attaching inserts. (Fig. 37).

Fig. 37 INSTALLING ASSEMBLY INSERTS INTO

RIVETING TOOL

1 - SPECIAL TOOL #8947 2 - SPECIAL TOOL #8952

NOTE: The outer plate will be held in place by a magnet.

(6) Place new outer plate into tool insert.

NOTE: Ensure that the riveted link and riveting tool are aligned.

(7) Position riveting tool over new link and press

in new rivet as far as the tool stop.

(8) Remove riveting tool to change inserts.

(9) Install insert on riveting tool and secure with screw.

(10) Install insert on riveting tool (Fig. 38).

NOTE: The outer plate is held in place magnetically by riveting tool.

(11) Insert new outer plate into the moving assembly insert.

(12) Position riveting tool so that spacer webs of the guide are side by side.

(13) Ensure that riveted link and outer plate are aligned.

Fig. 38 INSTALLING RIVETING INSERTS INTO

RIVETING TOOL

1 - SPECIAL TOOL #8947 2 - SPECIAL TOOL #8949

(16) Turn over tool moving assembly insert to the

riveting profile.

NOTE: Rivet pins of the riveted link individually.

(17) Position riveting tool exactly over middle of

pin (Fig. 39).

NOTE: When turning spindle of riveting tool, be sure that pins of riveted link are inserted into holes of outer plate.

(14) Screw in spindle of riveting tool until firm resistance is felt.

(15) Remove riveting tool.

Fig. 39 RIVETING NEW LINK

1 - RIVETING TOOL 2 - OIL PUMP CHAIN

Page 98

WG ENGINE 9a - 45

OIL PUMP (Continued)

(18) Tighten riveting tool spindle until it stops.

(19) Remove riveting tool, inspect riveting, rerivet if necessary (Fig. 40).

(20) Repeat procedure for both rivets.

Fig. 40 RIVET INSPECTION

(21) Install oil pump (Refer to 9 - ENGINE/LUBRICATION/OIL PUMP - INSTALLATION).

(22) Install oil pan (Refer to 9 - ENGINE/LUBRICATION/OIL PAN - INSTALLATION).

(23) Refill engine with proper oil to the correct level.

(24) Connect negative battery cable.

WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN DIRECT LINE WITH FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELT OR FAN. DO NOT WEAR LOOSE CLOTHES.

(25) Start engine and inspect for leaks.

OIL COOLER & LINES

REMOVAL - OIL COOLER

(1) Disconnect negative battery cable.

(2) Remove engine cover (Refer to 9 - ENGINE REMOVAL).

(3) Unscrew oil filter housing cap.

(4) Raise and suitably support vehicle.

WARNING: DO NOT OPEN COOLING SYSTEM UNLESS TEMPERATURE IS BELOW 90°C (194°F). OPEN CAP SLOWLY TO RELEASE PRESSURE. STORE COOLANT IN A MARKED AND SUITABLE CONTAINER. WEAR PROTECTIVE GLOVES, CLOTHING AND EYE WEAR.

NOTE: Collect any residual fluids that may flow.

(5) Drain engine coolant.

(6) Remove fuel full-flow filter (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL FILTER / WATER SEPARATOR - REMOVAL).

(7) Remove coolant hose from exhaust heat exchanger.

(8) Remove bolts attaching exhaust heat exchanger to cylinder head.

(9) Remove air charge distribution pipe (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYSTEM - REMOVAL).

(10) Remove coolant hose at oil-water heat exchanger.

NOTE: Collect any residual fluids that may flow.

(11) Remove automatic transmission fluid line at oil-water heat exchanger.

(12) Remove oil-water heat exchanger at timing case cover.

INSTALLATION - OIL COOLER

(1) Install oil cooler to timing case cover. Tighten bolts to 15 N·m (132 lbs. in.).

(2) Install transmission fluid lines to oil cooler.

(3) Install coolant hose to oil cooler.

(4) Install air charge distribution pipe (Refer to 11

- EXHAUST SYSTEM/TURBOCHARGER SYSTEM INSTALLATION).

(5) Install bolts attaching exhaust heat exchanger to cylinder head.

(6) Install coolant hose from exhaust heat exchanger.

(7) Install fuel full-flow filter (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL FILTER / WATER SEPARATOR - INSTALLATION).

(8) Close engine coolant drains.

(9) Install oil filter housing cap. Tighten to 25N·m (181 lbs. ft.).

(10) Install engine cover (Refer to 9 - ENGINE INSTALLATION). Tighten screws to 10N·m (89 lbs. in.).

(11) Refill coolant system to proper level with properly mixed coolant (Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE).

(12) Check engine oil level, refill with proper engine oil as necessary. Refer to owners manual for specifications.

WARNING: USE EXTREME CAUTION WHEN ENGINE IS OPERATING. DO NOT PUT YOUR HANDS NEAR PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHES.

Page 99

9a - 46 ENGINE WG

OIL COOLER & LINES (Continued)

(13) Start engine and inspect for leaks. (14) Inspect engine oil level 2 minutes after turn-

ing engine off. Refill as necessary.

INTAKE MANIFOLD

DESCRIPTION - INLET PORT SHUT OFF

A swirl and a charge air inlet port each are pro-

vided in the intake manifold for each cylinder (Fig.

41). The charge air ports can be closed by means of flaps. The flaps are connected to each other by linkage, which is operated by the inlet port shut off motor. The valves are held in position by means of spring force.

receives a PWM signal from the ECM for this purpose. A direct current motor pushes the adjusting lever into the correct position. If a fault or an open circuit occurs, the flaps are opened.

TIMING CHAIN COVER

REMOVAL

WARNING: DO NOT OPEN COOLING SYSTEM UNLESS TEMPERATURE IS BELOW 90°c (194°F). OPEN CAP SLOWLY TO RELEASE PRESSURE. STORE COOLANT IN APPROVED CONTAINER ONLY. RISK OF INJURY TO SKIN AND EYES FROM SCALDING COOLANT. WEAR PROTECTIVE GLOVES, CLOTHING AND EYE WEAR.

(1) Disconnect negative battery cable.

(2) Drain coolant (Refer to 7 - COOLING/ENGINE/ COOLANT - STANDARD PROCEDURE).

(3) Drain engine oil.

(4) Remove engine cover (Refer to 9 - ENGINE REMOVAL).

Fig. 41 SENSOR LOCATION

1 - CRANKSHAFT POSITION SENSOR 2 - SWIRL ACTUATOR

OPERATION - INLET PORT SHUT OFF

With lower engine speed and load range, all charge air ports are sealed off by way of flaps. The entire air flow flows in only through the swirl inlet ports. This results in a high air swirling which produces more effective mixing of fuel with air, enhancing combustion.

As engine speed and load rise, the charge inlet ports are continuously opened to obtain the best possible ratio between air swirling and air mass for each operating point. This optimizes engine power, exhaust characteristics, and reduces soot.

The position of the flaps in the charge air ports is determined by input received by the ECM (Engine Control Module). The inlet port shut off motor

NOTE: Inspect condition of hoses and clamps, replace as necessary.

(5) Detach coolant hoses on thermostat housing. (6) Remove air intake hose. (7) Remove air charge pipe together with air

charge hose.

(8) Remove hydraulic cooling fan (Refer to 7 -

COOLING/ENGINE/RADIATOR FAN - REMOVAL).

(9) Remove viscous heater hose and set aside.

(10) Remove fuel high pressure lines and injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/ FUEL INJECTOR - REMOVAL).

(11) Remove cylinder head cover (Refer to 9 ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).

NOTE: Rotate engine on crankshaft. DO NOT crank the engine at the bolt of the camshaft sprocket.

NOTE: DO NOT crank engine back.

Page 100

WG ENGINE 9a - 47

TIMING CHAIN COVER (Continued)

(12) Position piston of cylinder 1 to ignition TDC.

Markings on the camshaft bearing cap must be aligned.

(13) Install retaining lock for crankshaft/starter

ring gear.

(14) Remove timing chain tensioner (Refer to 9 ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL)

(15) Release rail on bracket.

(16) Remove coolant thermostat (Refer to 7 COOLING/ENGINE/ENGINE COOLANT THERMOSTAT - REMOVAL).

(17) Remove cylinder head front cover (Refer to 9 ENGINE/CYLINDER HEAD - REMOVAL).

(18) Remove belt pulley of power steering pump.

NOTE: NO NOT open the air conditioning system.

(19) Unplug AC compressor electrical connector and unbolt AC compressor. Relocate in lower engine compartment with out opening the system.

(20) Detach the coolant hose to oil-water heat exchanger at crankcase.

(21) Detach and plug the transmission oil lines to oil-water heat exchanger.

(22) Detach coolant hoses on coolant pump.

(23) Remove water pump (Refer to 7 - COOLING/ ENGINE/WATER PUMP - REMOVAL).

(24) Remove air charge pipe.

(25) Remove generator (Refer to 8 - ELECTRICAL/ CHARGING/GENERATOR - REMOVAL).

(26) Remove belt/pulley vibration damper.(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION

DAMPER - REMOVAL).

NOTE: Remove the bolts in area of timing case cover. Loosen all other oil pan bolts.

(27) Remove oil pan bolts.

(28) Remove M8 bolts of cylinder head on timing case cover.

(29) Remove timing case cover (Fig. 42).

(30) Remove remaining ancillary components attached to the timing case cover.

INSTALLATION

NOTE: Thoroughly clean all mating surfaces with the appropriate solvents to assure that no grease or oil is present during assembly.

(1) Inspect cylinder head gasket and oil pan gasket. If damaged, replace.

(2) Replace the front crankshaft seal (Refer to 9 ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - FRONT - INSTALLATION).

1 - INTERMEDIATE GEAR 2 - TIMING CHAIN COVER 3 - TENSIONING RAIL 4 - BEARING PIN 5 - OIL PAN

(3) Install ancillary components to timing case

cover.

(4) Position and install timing case cover. Tighten

bolts to 20 N·m (177 lbs in).

(5) Install the M8 bolts of cylinder head on timing

case cover. Tighten bolts to 20 N·m (177 lbs in).

(6) Position and install the oil pan. Tighten M6 bolts to 9 N·m (80 lbs in) and M8 bolts to 20 N·m (177 lbs in).

(7) Install belt /pulley vibration damper. Tighten M8.8 bolt in two stages, 200N·m (147 lbs ft.) then 90°, M10.9 bolt 325N·m (240 lbs ft) then 90°.

(8) Install generator (Refer to 8 - ELECTRICAL/ CHARGING/GENERATOR - INSTALLATION).

(9) Install air charge pipe (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYSTEM - INSTALLATION).

(10) Install water pump (Refer to 7 - COOLING/ ENGINE/WATER PUMP - INSTALLATION).

(11) Connect coolant hoses to water pump.

(12) Connect the transmission oil lines to oil-water heat exchanger.

(13) Connect coolant hose to oil-water heat exchanger.

Fig. 42 TIMING CHAIN COVER