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1.6L Diesel: Removal

  1. Remove the battery. Refer to BATTERY, REMOVAL AND INSTALLATION and BATTERY, SUPPLEMENTAL, REMOVAL AND INSTALLATION .
  2. Remove the engine cover. Refer to the appropriate Service Information .
  3. Remove the belly pan. Refer to BELLY PAN, REMOVAL AND INSTALLATION .
  4. Drain the cooling system. Refer to STANDARD PROCEDURE .
    GC0162269Courtesy of CHRYSLER GROUP, LLC
  5. Remove the bolt (1) securing the left Charge Air Cooler (CAC) tube.
    GC0162295Courtesy of CHRYSLER GROUP, LLC
  6. Open the retaining clip (1a) and disconnect the vacuum brake booster hose (1b) quick-disconnect fitting (1b).
    GC0162333Courtesy of CHRYSLER GROUP, LLC
  7. Remove the bolts (1a) and the CAC tube (1b).
    GC0165365Courtesy of CHRYSLER GROUP, LLC
  8. Loosen the clamp and remove the coolant hose (1) from the thermostat housing.
  9. Loosen the clamp and remove the radiator hose (2) from the thermostat housing.
  10. Remove bolts (3a) and the thermostat housing (3b).

INSTALLATION 

GC0164549Courtesy of CHRYSLER GROUP, LLC
  1. Using a NEW  gasket, install the thermostat housing (1a) Tighten the bolts (1b) to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
  2. Install the radiator hose (2) onto the thermostat housing and tighten the clamp.
  3. Install the coolant hose (3) onto the thermostat housing and tighten the clamp.
    GC0162333Courtesy of CHRYSLER GROUP, LLC
  4. Using a NEW  O-ring seal, install the left charge Air Cooler (CAC) tube (1b). Tighten the bolts (1a) to the proper specification. Refer to TECHNICAL SPECIFICATIONS  .
    GC0162295Courtesy of CHRYSLER GROUP, LLC
  5. Connect the vacuum brake booster hose (1b) quick-disconnect fitting (1b) and close the retaining clip (1a).
    GC0162269Courtesy of CHRYSLER GROUP, LLC
  6. Install the bolt (1) securing the left CAC tube and tighten to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
  7. Fill the cooling system. Refer to STANDARD PROCEDURE .
  8. Install the engine cover. Refer to the appropriate Service Information .
  9. Install the battery. Refer to BATTERY, REMOVAL AND INSTALLATION and BATTERY, SUPPLEMENTAL, REMOVAL AND INSTALLATION .
  10. Run engine to operating temperature and check for leaks.
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