Dodge Sprinter. Manual — part 218
(11) Install the torque converter access plate. Refer
to (Refer to 21 - TRANSMISSION/TRANSAXLE/AU-
TOMATIC - NAG1 - INSTALLATION) for correct
sequence and torque specification.
(12) Install the transmission cooler lines to trans-
mission. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - NAG1 - INSTALLATION) for
correct sequence and torque specification.
(13) Connect the engine valley drain hose to the
transmission (Fig. 5).
(14) Install transmission electrical connector and
shifter hardware. Refer to (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/AUTOMATIC - NAG1 - INSTAL-
LATION)
for
correct
sequence
and
torque
specification.
(15) Install the steering gear and tighten in two
stages. 25 N·m (18.5 lbs. ft.), then 45 N·m (33 lbs. ft.)
plus 90°.
(16) Install the starter.
(17) Connect the ground strap (left side).
(18) Align and install the exhaust and bracket
(Refer to 11 - EXHAUST SYSTEM/EXHAUST PIPE -
INSTALLATION).
(19) Lower the vehicle.
(20) Install the lower heater housing and filter.
(21) Install the air inlet hose, CCV breather and
CCV heater at the turbocharger (Fig. 4).
(22) Connect the coolant supply and return hoses.
(23) Connect the brake booster vacuum hose at the
vacuum pump.
(24) Connect the fuel lines at the filter assembly
(Fig. 9).
(25) Connect the power steering hoses.
(26) Install the radiator/charge air cooler and
hose(s) assemblies (Refer to 7 - COOLING/ENGINE/
RADIATOR - INSTALLATION).
(27) Install A/C condenser and fan assemblies Con-
nect the fan harness connector.
(28) Connect the refrigerant lines.
(29) Install a air conditioning receiver/drier (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/RECEIVER / DRIER - INSTALLATION).
(30) Connect the upper and lower radiator hoses.
(31) Connect the transmission lines at the radia-
tor.
(32) Install air cleaner housing and connect the air
inlet duct and air flow sensor.
(33) Connect the charge air cooler hose at intake
manifold. (Refer to 9 - ENGINE/AIR INTAKE SYS-
TEM/AIR CLEANER HOUSING - INSTALLATION).
(34) Route the engine wiring harness inside the
vehicle and connect.
(35) Install the turbocharger heat shield.
(36) Install the front grille and fascia assembly.
(37) Connect the negative battery cable.
(38) Check and fill engine oil (Refer to LUBRICA-
TION & MAINTENANCE/FLUID TYPES - SPECIFI-
CATIONS).
Fig. 8 CRANKSHAFT POSITION SENSOR
1 - ENGINE BLOCK
2 - WIRING HARNESS CONNECTOR
3 - CRANKSHAFT POSITION SENSOR
4 - STARTER SOLENOID
Fig. 9 FUEL FILTER
1 - FUEL SUPPLY FROM TANK
2 - FUEL SUPPLY TO HIGH PRESSURE PUMP
3 - POWER STEERING RESERVOIR
4 - FUEL FILTER
5 - OIL FILTER
6 - WATER IN FUEL SENSOR
9 - 10
ENGINE
VA
(39) Fill cooling system to proper level with the
appropriate coolant.
(40) Evacuate and recharge air conditioning.
(41) Check and refill all ancillary system fluid lev-
els.
(42) Start engine and inspect for leaks (Refer to 14
- FUEL SYSTEM - WARNING).
SPECIFICATIONS - TORQUE SPECIFICATIONS
2.7L DIESEL
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Crankcase Ventilation
Screw-Air Charge Distri-
bution Pipe to Air Charge
Distribution Panel
11
-
97
Cylinder Head
8m-Bolt- Cylinder Head to
Timing Case Cover
20
15
-
Bolt-Front Cover to Cylin-
der Head
14
-
124
12m-Bolt-Cylinder Head
to Crankcase (3 stages,
torque, torque angle,
torque angle)
60, 90°, 90°
44, 90°,90°
-
Crankcase, Timing Case
Cover, End Cover
Bolt-Crankshaft Bearing
Cap to Crankcase (2
stages, torque, torque an-
gle)
55, 90°
40, 90°
-
Bolt-End Cover to Crank-
case
9
-
80
Bolt-Timing Case Cover
to Crankcase
20
15
-
Plug-Coolant Drain to
Crankcase
30
22
-
Oil Pan
6m-Bolt-Oil Pan to Crank-
case
9
-
80
8m-Bolt-Oil Pan to Crank-
case
20
15
-
Bolt-Oil Pan to End Cover
9
-
80
Bolt-Oil Pan to Timing
Case Cover
9
-
80
Bolt-Oil Pan to Transmis-
sion Bell Housing
40
30
-
Plug-Oil Pan to Oil Drain
47
35
-
Connecting Rod
VA
ENGINE
9 - 11
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Bolt-Connecting Rod Cap
to Connecting Rod (3
stage, 1&2 torque, 1
torque angle)
5,25,90°
-
44,221, 90°
Crankshaft
Bolt-Crankshaft Bearing
Cap (2 stage, 1 torque, 1
torque angle
55,90°
40.5, 90°
-
Flywheel, Driven Plate, Vibration Damper, Starter Ring Gear
8.8m-Bolt-Central Bolt of
Vibration Damper (2
stage, 1 torque, 1 torque
angle)
200,90°
147.5, 90°
-
10.9m-Bolt-Central Bolt of
Vibration Damper (2
stage, 1 torque, 1 torque
angle)
325,90°
240, 90°
-
Bolt-Stretch Shank for
Flywheel or 2 Mass Fly-
wheel to Crankshaft (2
stage, 1 torque, 1 torque
angle)
45,90°
33, 90°
Turbo Charger
Bolt-Oil Feed Line to Cyl-
inder Head
9/22
-
80-194
Bolt-Oil Feed Line to Tur-
bo Charger
30
22
-
Bolt-Turbo Charger Sup-
port
30
22
-
Bolt-Turbo Charger Sup-
port to Crankcase
20
-
177
Bolt-Oil Outlet Line to
Turbo Charger
9
-
80
Connection-Flange of Ex-
haust Manifold to Turbo
Charger
30
22
-
Connection-Turbo Charger
to Front Catalytic Con-
verter
30
22
-
Charge Air Pipe/Charge Air Cooling
Bolt-Charge Air Distribu-
tion Pipe
16
-
141
Bolt-Inlet Port Shut Off
Positioning Motor to Air
Charge Distribution Pipe
9
-
80
Bolt-Support to Charge
Air Distribution Pipe
20
-
177
Bolt-Support to Engine
Bracket
40
30
-
9 - 12
ENGINE
VA
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Clamp-Charge Air Pipes/
Hoses
3
-
27
Belt Tensioning Device
Bolt-Guide Pulley to Cool-
ant Pump
35
26
-
Bolt-Guide Pulley to Tim-
ing Case Cover
35
26
-
Bolt-V-Belt Tensioning De-
vice to Tensioning Pulley
36
26.5
-
Bolt-V-Belt Tensioning De-
vice to Timing Case Cov-
er
30
22
-
Exhaust Manifold
Nut-Exhaust Manifold at
Cylinder Head
30
22
-
Position Sensor
Nut/Bolt-Camshaft Posi-
tion Sensor to Cylinder
Head Cover
11
-
97
Nut/Bolt-Crankshaft Posi-
tion Sensor to Engine
Block
8
-
70
Pre-Glow System
Cylinder Head to Glow
Plug
12
-
106
Starter
Bolt-Starter to Crankcase
42
31
-
Nut-Connection of Circuit
30
14
-
124
Nut-Connection of Circuit
50
6
-
53
Alternator
Bolt-Generator to Timing
Case Cover
20
15
-
Bolt-Generator to Cooler
Housing
6
-
53
Bolt-Cooler Housing of
Generator to Crankcase
20
-
177
Nut-B+ Circuit to Genera-
tor
13-18
-
115-159
Nut-D+ Circuit to Genera-
tor
5
-
44
Nut-Collar to V-Belt Pulley
80
59
-
Oil Pump
Bolt-Oil Pump to Crank-
case
18
-
133
Bolt-Oil Pipe to Crank-
shaft Bearing Cap
8
-
70
VA
ENGINE
9 - 13
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