Dodge Sprinter. Manual — part 230
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 #9746 (3) and a slide
hammer (1), remove the oil jets (2) from engine block
(Fig. 54).
INSTALLATION
(1) Install oil jet into special tool #8924.
(2) Align oil jet in location in engine block.
NOTE: Align oil jet with the groove in special tool
#8924.
(3) Drive oil jets into block using special tool #8924
until oil jet is fully seated into engine block (Fig.
55).
(4) Reassemble engine.
(5) Install engine into vehicle.
OIL PAN
REMOVAL
(1) Drain engine oil.
(2) Remove the sway bar retaining bolts and swing
sway bar down and out of the way.
(3) Remove the wiring harness duct from the oil
pan bolts and position out of the way.
(4) Lower the vehicle and remove the turbocharger
upper heat shield.
(5) Connect engine support fixture #8534 using
adaptors #8534–16, to the engine lifting eye and
raise engine slightly (Fig. 56).
Fig. 53 OIL JET LOCATION
1 - ENGINE BLOCK
2 - OIL JET
Fig. 54 OIL JET EXTRACTION CLAW
1 - SLIDE HAMMER
2 - OIL JETS
3 - EXTRACTION CLAW # 9746
Fig. 55 OIL JET INSTALLATION
1 - OIL JET INSTALLER #8942
2 - ENGINE BLOCK
3 - OIL JET
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ENGINE
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(6) Remove engine mounts and raise engine.
(7) Disconnect the oil level sensor.
(8) Remove the transmission cooler lines from the
oil pan bolts and carefully position the lines aside
(9) Remove the oil pan bolts.
(10) Remove oil pan and gasket (Fig. 57).
Fig. 56 ENGINE SUPPORT FIXTURE
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ENGINE
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INSTALLATION
NOTE: Oil pan bolts are of different diameters and
lengths. Care must be take to install the bolts in
their original position (Fig. 59).
NOTE: Clean the strainer of the oil pump. If the oil
pump is dry, coat the inside with clean engine oil.
NOTE: Thoroughly clean all mating surfaces with
the appropriate solvents to assure that no grease or
oil is present during reassembly.
(1) Slide the oil pan into position.
(2) Slide the gasket into position.
(3) Add sealant to the joints on the engine block
where indicated (Fig. 58).
Fig. 57 OIL PAN
1 - O-RING
6 - CONNECTOR FOR OIL LEVEL SENSOR
2 - OIL PUMP
7 - OIL PAN
3 - GASKET
8 - TRANSMISSION LINE
4 - WIRING HARNESS DUCT
9 - OIL PUMP CHAIN
5 - TRANSMISSION LINE
10 - OIL PUMP CHAIN TENSIONER
Fig. 58 OIL PAN GASKET
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ENGINE
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(4) Install the oil pan. Tighten M6 bolts to 9N·m
(80 lbs. in.) and M8 bolts to 20N·m (15 lbs. ft.) (Fig.
59).
(5) Tighten the bolt of the transmission bell hous-
ing to oil pan to 40N·m (30 lbs. ft.).
(6) Install the wiring harness duct (Fig. 57).
(7) Connect the oil level sensor (Fig. 57).
(8) Lower the vehicle.
(9) Lower the engine until the engine mount and
engine supports make contact.
(10) Start and hand tighten the engine mount
bolts.
(11) Lower the engine the rest of the way and
remove the engine support fixture.
(12) Tighten the engine mount bolts to 83 N·m (61
lbs. ft.).
(13) Install the sway bar and tighten bolts to 30
N·m (22 lbs. ft.).
(14) Refill crankcase with the proper engine oil to
the proper level (Refer to LUBRICATION & MAIN-
TENANCE/FLUID TYPES - SPECIFICATIONS).
(15) 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.
(16) Start the engine and inspect for leaks.
OIL PUMP
REMOVAL
REMOVAL
(1) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(2) Remove the oil pump bolts (Fig. 57).
(3) Press the chain tensioner off of the oil pump
chain, and remove pump from chain.
(4) Remove the oil pump, pick-up tube and O-ring
(Fig. 57).
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).
NOTE: Make sure the pin of the thrust spindle is
backed out into the thrust spindle before seating
the thrust spindle to the oil pump chain.
(4) Using special tool #9312–1 riveting tool, thrust
spindle #9312–4 and thrust pin pin #9312–3, position
and fit chain seperating tool and thrust spindle onto
a link of the oil pump chain (Fig. 60).
(5) Screw the thrust pin in and seperate the oil
pump chain link.
Fig. 59 OIL PAN BOLTS
1 - M8X40
2 - M8X50
3 - M6X85
4 - M6X20
5 - M6X35
6 - M10X55
Fig. 60 OIL PUMP CHAIN LINK REMOVAL
1 - VIBRATION DAMPER/PULLEY
2 - OIL PUMP CHAIN
3 - SPECIAL TOOL #9312-1
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ENGINE
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