Dodge Sprinter 2.7L Engine Replacing Procedure?

In this chapter Complete details are provided replace ENGINE on Dodge Sprinter Truck/VAN models.

The procedure is provided with complete details and diagrams.

The Engine replacing is as follows:----

2.7L Engine:---

1. Disconnect the negative battery cable.
2. Drain the cooling system.
3. Evacuate and recover the A/C refrigerant.
4. Remove the front grille and fascia assembly.
5. Disconnect the engine wiring harness at the cabin side and carefully guide though the cowl into the engine area.
6. Remove the turbocharger heat shield.
7. Remove the engine appearance cover.
8. Remove the air cleaner and hose at the turbocharger and air cleaner assembly.
9. Disconnect the transmission lines at the radiator.
10. Disconnect the upper and lower radiator hoses.
11. Disconnect the A/C lines at the condenser.
12. Disconnect the condenser fan harness connector.
13. Disconnect the power steering cooler lines at the cooler.
14. Disconnect the charge air cooler hose at the intake manifold.
15. Remove charge air hose fasteners at the radiator closure panel.
16. Remove the fasteners retaining the radiator to the front crossmember.
17. Remove the change air cooler, A/C condenser and fan as an assembly.
18. Disconnect the charge air hose at the intake manifold.
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.
24. Disconnect the coolant hose of heating return flow at the water pump.
25. Disconnect the coolant hose of the heater supply at the coolant pipe at the side of the cylinder head.
26. Disconnect the air inlet, CCV breather hoses and CCV heater at the turbocharger.
27. Raise and safely support the vehicle.
28. Disconnect the front exhaust at the turbocharger.
29. Disconnect the electrical connector at the transmission.
30. Disconnect the engine valley drain hose fastener from the transmission.
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.
38. Support the transmission with a suitable 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 Special Tool 9308 Engine Lifting Fixture to the engine lifting eyes. 
    
    
    
    Fig. Attach Special Tool 9308 (3) to the engine, then connect the engine hoist (1) to the center eyelet (2)-2.7L Engine removal
46. Remove the engine mount bolts.
47. Remove the transmission oil level indicator tube mounting bolt.
48. Using tin snips, remove the front cross plate at the cutting edges and deburr.
    
    
    
    Fig. Cut the front cross plate (2) at the area indicated (1)-2.7L Engine removal
49. Connect and engine hoist and carefully lift engine assembly from engine bay area.

To install:

1. Install the engine assembly into the vehicle engine compartment, mating the transmission and the engine.
2. Lower the engine assembly until the engine brackets align with the mounts.
3. Hand start the engine mount bolts and remove the engine lifting device. Tighten the engine mount bolts to 62 ft. lbs. (83 Nm).
4. Raise and safely support the vehicle.
5. Install the transmission housing to engine bolts. For additional information, refer to the following section, "Automatic Transmission, Removal & Installation.-
6. Install the torque converter bolts. For additional information, refer to the following section, "Automatic Transmission, Removal & Installation.-
7. Install the crankshaft position sensor.
8. Install the torque converter access plate.
9. Install the transmission cooler lines to transmission.
10. Connect the engine valley drain hose to the transmission.
11. Install the transmission electrical connector and shifter hardware.
12. Install the steering gear.
13. Install the starter.
14. Connect the ground strap (left side).
15. Align and install the exhaust and bracket.
16. Lower the vehicle.
17. Install the lower heater housing and filter.
18. Install the air inlet hose, CCV breather and CCV heater at the turbocharger.
19. Connect the coolant supply and return hoses.
20. Connect the brake booster vacuum hose at the vacuum pump.
21. Connect the fuel lines at the filter assembly.
22. Connect the power steering hoses.
23. Install the radiator/charge air cooler and hose(s) assemblies.
24. Install A/C condenser and fan assemblies Connect the fan harness connector.
25. Connect the refrigerant lines.
26. Install an air conditioning receiver/drier.
27. Connect the upper and lower radiator hoses.
28. Connect the transmission lines at the radiator.
29. Install air cleaner housing and connect the air inlet duct and air flow sensor.
30. Connect the charge air cooler hose at intake manifold.
31. Route the engine wiring harness inside the vehicle and connect.
32. Install the turbocharger heat shield.
33. Install the front grille and fascia assembly.
34. Check and fill the engine oil.
35. Refill the cooling system to the correct level.
36. Evacuate and recharge the A/C refrigerant.
37. Start engine and check for leaks

These details will help.

Thanks.           

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html