Friday, April 20, 2012

How to replace 3.5L Engine on Dodge Sprinter?

Here is the detailed procedure provided for replacing Engine on Dodge Sprinter Truck and Van models.

The Procedure for 3.5L Engine replacing.

The Procedure starts here:---

  1. 3.5L Engine
  2. Disconnect the negative battery cable.
  3. Drain the cooling system.
  4. Drain the engine oil.
  5. Drain the power steering fluid.
  6. Remove the air intake assembly.
  7. Remove the grill.
  8. Remove the headlight trim panel.
  9. Raise and safely support the vehicle.
  10. Remove the license plate holder and step grip plate.
  11. Remove the front fascia assembly.
  12. Lower the vehicle.
  13. Drain the power steering fluid from the power steering fluid reservoir.
  14. Disconnect the power steering fluid lines.
  15. Disconnect the A/C pressure sensor.
  16. Remove the condenser line bolt.
  17. Remove the condenser lines.
  18. Remove the transmission cooler lines from the radiator.
  19. Remove the heater hose lines from the extension line.
  20. Remove the upper and lower radiator hoses.
  21. Match-mark the radiator support location on the frame.
  22. Disconnect the electric fan connector.
  23. Remove the cooling module assembly.
  24. Disconnect the canister purge lines and position aside.
  25. Disconnect the fuel lines.
  26. Disconnect the fuel lines at the fuel rail.
  27. Disconnect the Powertrain Control Module (PCM) connectors and remove the PCM
  28. Remove the transmission dip stick mounting bolts.
  29. Disconnect the engine ground strap.
  30. Disconnect the coolant level sensor.
  31. Raise and safely support the vehicle.
  32. Remove the torque converter bolts.
  33. Disconnect the oxygen sensor connectors at the connector bracket.
  34. Remove the bolts from the right and left exhaust flange.
  35. Remove the starter. For additional information, refer to the following section, "Starter, Removal & Installation.-
  36. Disconnect the alternator electrical connectors.
  37. Remove all but the top bell housing bolt.
  38. Remove the left motor mount bolt.
  39. Remove the left motor mount bolt.
  40. Lower the vehicle.
  41. Support the transmission with a suitable jack.
  42. Install a suitable engine lift to the engine.
  43. Remove the last bellhousing bolt.
  44. Remove the engine assembly from the vehicle.

To install:
  1. Using an engine lift, lower the engine assembly into the vehicle.
  2. Install a single bell-housing bolt and tighten to 28 ft. lbs. (38 Nm).
  3. Install the right motor mount bolt and tighten to 42 ft. lbs. (58 Nm).
  4. Install the left motor mount bolt and tighten to 42 ft. lbs. (58 Nm).
  5. Remove the jack supporting the transmission assembly and remove the engine lift.
  6. Connect the alternator electrical connector.
  7. Install the remaining bellhousing bolts and tighten to 28 ft. lbs. (38 Nm).
  8. Install the torque converter bolts and tighten to 37 ft. lbs. (50 Nm).
  9. Install the starter motor.
  10. Install the bolts for the left and right exhaust flanges and tighten to 15 ft. lbs. (20 Nm).
  11. Connect the oxygen sensor electrical connectors.
  12. Install the front lower sound shield.
  13. Connect the coolant level sensor.
  14. Connect the engine ground strap.
  15. Install the transmission dipstick mounting bolts.
  16. Install the PCM and connect the electrical connectors.
  17. Connect the fuel lines to the fuel rail.
  18. Connect the canister purge lines.
  19. Connect the electric fan connector.
  20. Install the radiator support. Make sure the radiator support location lines up with the marks made on the frame during the removal process.
  21. Install the upper and lower radiator hose.
  22. Install the heater hose lines to the extension line.
  23. Install the transmission cooler lines to the radiator.
  24. Install the condenser lines.
  25. Connect the A/C pressure sensor.
  26. Connect the power steering fluid lines.
  27. Install the front fascia assembly.
  28. Install the license plate holder and step grip plate.
  29. Install the head lamp trim panel.
  30. Install the grill assembly.
  31. Install the air intake assembly.
  32. Refill the engine with oil to the correct level.
  33. Refill the power steering system with fluid to the correct level.
  34. Refill the cooling system to the correct level.
  35. Connect the negative battery cable.
  36. Start the engine and check for leaks.

These details will help.


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