Dodge Sprinter. Manual — part 217
(6) Remove the turbocharger heat shield (Fig. 3).
(7) Remove the engine cover (Fig. 3).
(8) Remove the air cleaner and hose at the turbo-
charger and air cleaner assembly.
(9) Disconnect the transmission lines at the radia-
tor.
(10) Disconnect the upper and lower radiator
hoses.
(11) Disconnect the A/C lines at the condenser.
(12) Disconnect the condenser fan harness connec-
tor.
(13) Disconnect the power steering cooler lines at
the cooler.
(14) Disconnect the charge air cooler hose at the
intake manifold (Fig. 3).
(15) Remove charge air hose fasteners at the radi-
ator closure panel.
(16) Remove the fasteners retaining the radiator to
the front crossmember.
(17) Remove the change air cooler, A/C conderser
and fan as an assembly.
(18) Disconnect the charge air hose at the intake
manifold (Fig. 3).
(19) Remove the radiator assembly.
(20) Disconnect the high pressure and return
hoses at the power steering pump.
(21) Disconnect the fuel lines at the fuel filter.
(22) Disconnect the refrigerant line at the A/C
compressor.
(23) Disconnect the vacuum line for the brake
booster at the vacuum pump (Fig. 3).
(24) Disconnect the coolant hose of heating return
flow at the water pump.
(25) Disconnect the coolant hose of the heater sup-
ply at the coolant pipe at the side of the cylinder
head.
Fig. 3 ENGINE COVER
1 - ENGINE COVER
6 - HIGH PRESSURE FUEL PUMP
2 - FUEL RAIL
7 - VACUUM PUMP
3 - INTAKE MANIFOLD
8 - OIL LEVEL INDICATOR
4 - EGR VALVE
9 - HEAT SHIELD
5 - AIR INLET TUBE
10 - TRANSMISSION OIL LEVEL INDICATOR
9 - 6
ENGINE
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(26) Disconnect the air inlet, CCV breather hoses
and CCV heater at the turbocharger (Fig. 4).
(27) Raise and support the vehicle.
(28) Disconnect the front exhaust at the turbo-
charger (Fig. 4).
(29) Disconnect the electrical connector at the
transmission.
Fig. 4 TURBOCHARGER INLET
1 - CCV BREATHER
5 - MAF SENSOR
2 - OIL LEVEL INDICATOR
6 - AIR CLEANER COVER
3 - CCV HEATER
7 - TURBOCHARGER
4 - TURBOCHARGER INLET HOSE
8 - EXHAUST PIPE
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ENGINE
9 - 7
(30) Disconnect the engine valley drain hose fas-
tener from the transmission (Fig. 5).
(31) Remove the steering gear mounting bolts.
(32) Disconnect the transmission cooler lines at
transmission and oil pan.
(33) Remove the torque converter access plate.
(34) Remove the torque converter bolts.
(35) Remove the crank position sensor.
(36) Remove the transmission housing to engine
mounting bolts.
(37) Remove the starter mounting bolts (Fig. 5).
(38) Support the transmission with a transmission
jack.
(39) Place a wood block between the transmission
housing and the front frame cross over.
(40) Remove the transmission jack.
(41) Remove the exhaust bracket (right side).
(42) Remove the engine ground strap (left side).
(43) Lower the vehicle.
(44) Remove the heater housing filter and lower
housing.
(45) Connect the engine lifting fixture #9308 to the
engine lifting eyes.
(46) Remove the engine mount bolts.
(47) Remove the transmission oil level indicator
tube mounting bolt.
Fig. 5 2.7L CDI ENGINE
1 - INTAKE MANIFOLD
5 - FUEL FILTER
2 - ENGINE VALLEY DRAIN HOSE
6 - AIR CONDITIONING COMPRESSOR
3 - STARTER
7 - POWER STEERING PUMP
4 - ENGINE OIL LEVEL SENSOR
8 - EGR VALVE
9 - 8
ENGINE
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NOTE: After removing the front cross plate, seal
metal with anti corrosion protection.
(48) Using tin snips, remove the front cross plate
at the cutting edges and deburr (Fig. 6).
(49) Connect and engine hoist and carefully lift
engine assembly from engine bay area (Fig. 7).
INSTALLATION
INSTALLATION - ENGINE COVER
CAUTION: Care must be taken when installing the
engine cover. Assure the proper routing of the fuel
injector return fuel hose to the banjo bolt fitting in
the left rear corner of the cover. Failure to do so
may pinch or damage the hose causing fuel leakage
or a driveability concern.
(1) Align cover and install screws. tighten screws
to 11N·m (97 lbs. in.) (Fig. 2).
INSTALLATION
NOTE: Deburr and seal metal from cross plate
removal with anti corrosion material.
NOTE: Replace the air conditioning drier any time
the air conditioning system is opened to the atmo-
sphere.
(1) Install the engine lifting fixture, special tool #
9308 to the engine lifting eyelets.
(2) Attach the engine hoist.
(3) Install the engine assembly into the vehicle
engine compartment, mating the transmission and
the engine.
(4) Lower the engine assembly until the engine
brackets align with the mounts.
(5) Hand start the engine mount bolts and remove
the engine lifting devise.
(6) Tighten the engine mount bolts to 83 N·m (62
lbs.ft.).
(7) Raise and support the vehicle.
(8) Install the transmission housing to engine
bolts. Refer to (Refer to 21 - TRANSMISSION/
TRANSAXLE/AUTOMATIC - NAG1 - INSTALLA-
TION) for correct sequence and torque specification.
(9) Install the torque converter bolts. Refer to
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - NAG1 - INSTALLATION) for correct
sequence and torque specification.
(10) Install the crank sensor (Fig. 8).
Fig. 6 FRONT CROSS PLATE
1 - CUTTING POINT
2 - CORE SUPPORT
Fig. 7 ENGINE HOIST CONNECTION
1 - ENGINE HOIST
2 - CENTER EYELET OF ENGINE LIFTING FIXTURE
3 - ENGINE LIFTING FIXTURE #9308
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ENGINE
9 - 9
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