The Mopar Advantage - Chrysler

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The Mopar advantage Diesel engines and partsWhen most people look at an engine, they see the whole engine. Mopar Remanufacturing, however, sees the hundreds of parts that arenecessary to provide reliable power. In addition, Mopar puts a great deal of effort into remanufacturing an extremely wide variety ofhard-to-find parts, so it can provide a replacement engine for almost any vehicle. Here are some examples of key engine componentsthat get special attention from Mopar Remanufacturing.Cylinder Head Assembly — Mopar will still remanufacture the cylinder heads when a completeengine replacement isn’t necessary. Mopar Diesel In-Line, 6-cylinder heads use original equipment components and meet strict original equipment engineering standards. In addition, replacing only thecylinder heads when necessary saves the customer the cost of an entire engine.Water Pump Assemblies — Basic operations include pre-inspection, salvage, assembly, testingand packaging. Since seals, bearings, and the impeller are replaced 100%, the major focus of theremanufacturing operation centers on the body and pulley.Connecting Rods — The connecting rod is a key component that transfers power from the piston tothe crankshaft which, in turn, drives the diesel engine. These rods are inspected to detect potentiallydamaging cracks and to ensure a superfine finish on the wear surfaces. All rods are then checked with magnetic particle testing equipment, and each rod is torqued and rehoned to original specifications.Turbochargers — One of the fastest growing parts lines, more and more customers are discoveringthe advantages of a remanufactured diesel turbocharger. State-of-the-art processes are used toproduce high quality, reliable turbos. This technology includes laser micrometers, CNC lathes anddelicate balancing machines. When any turbo is in operation, the turbine wheel may reach speedsup to 100,000 rpm, so holding tight tolerances is critical to proper turbo performance.Fuel Injector —These components are crucial for distributing fuel to the cylinders. All critical partsare carefully examined using the latest in measuring and gauging technology. Every remanufacturedinjector must pass rigorous testing on customized high-tech calibration test stands and meet originalequipment specifications.140/diesel products/www.mopar.com

c ummi n s – d i e se l e ng in e s in fo r mat io nCPL IdentificationTo help you with product identification, Certified Parts List information is found on the engine data plate.This number will help determine the appropriate Chrysler LLC replacement part number.Fuel Side of Enginecplwww.mopar.com/diesel products/141

D ies el en g i n e sBelow is a helpful matrix identifying which engine parts are included with the reman engine assembly.Mopar reman engine matrixCylinder BlockCylinder Head(s)CrankshaftMain & Rod BearingsConnecting Rod setPiston, pin, rings setCamshaft(s)Valves and SpringsRocker ArmsRocker ShaftsPushrodsTappetsCyl. head gasket(s)valve cover(s) w/gaskets 579xxxxxxxxxxxxxxMODEL YearENGINEComplete engine assembliesLong block 4.5R5140910AAxxxxxxxxxxxxxx2004-2003R5093538AA (250 HP)xxxxxxxxxxxxxx2004-2003R5093540AA (305 74AAxxxxxxxxxxxxxxxShort block engine xxx1995-1994R4761368xxxxx**All Except 2007-2006 Mega Cab with Auto Trans.*Mega Cab with Auto Trans.142/diesel products/www.mopar.comx

Diesel e n g i n e s(continued)Mopar reman engine matrix (cont.)fuel injectorsfuel pumpturbochargerxxxxxxwooden skidintake manifoldxmetal skidexhaust manifoldxcardboard boxwater pumpxblue/yellow plastic crateoil panENGINEoil pickupmodel YEARoil pump Complete engine xLong block A (250 HP)xxxxxx2004-2003R5093540AA (305 6AAxxxxxx2000-1998.5R5016374AAxxxxxxShort block engine xxx**All Except 2007-2006 Mega Cab with Auto Trans.*Mega Cab with Auto Trans.www.mopar.com/diesel products/143

LONG BLO CK E N G I N E SFACTORY REMANUFACTUREDTO CHRYSLER llc STANDARDS100% new parts:Pistons, Rings, Gaskets, Seals, Hoses,Main Rod Bearings, Fuel Line, Filters, Lube Pumplong block kit contains: Remanufactured Short Block KitCamshaft and Camshaft GearRemanufactured Cylinder Head KitValve Cover and Oil PanRemanufactured Water Pump KitGear Cover*complete engine assembliescummins-diesel applicationsModel YearApplicationEngineTransEngine CPLReman Part No.Long Block Assemblies2008-20076.7L PickupETJAll8230, 8231, 8233, 8234R8036075AA2008-20076.7L Chassis CabETJAll1257, 1264, 2885, 8232R8003550AA2008-20065.9LETHDEG,DG81000, 1083, 1091, 1095, 8344, 8345, 8348, 8349 (325 HP)Not for use on Megacab 4X4 w/Auto TransR8001618AA2008-20065.9LETHDG81000, 1083, 8344, 8345 (325 HP)For use only on Megacab 4X4 w/Auto TransR8001619AA20055.9LETHDEG8423, 8424 (325 HP)Requires swapping Valve Cover & Rocker Housing from original engineR8001618AA2005-2004.55.9LETHDG8, DEE8346, 8347, 8350, 8351, 8421, 8422, 8423, 8424 (325 HP)2004.5 is designated by Sales Code XCKR5141910AA2004-20035.9LETHDG8, DEE2998, 8213, 8228 (High Output 305/555)R5093540AAETCAll2624, 8212, 8218, 8223, 8224, 8226, 8410, 8412 (Std. Output 235/460)R5093538AAETHDEE2415, 2495, 2906, 2907, 8034, 8035 (245 HP M/T)R5019756AAETCDG7,DDX2496, 2497, 2865, 2866, 2902, 2903, 2904, 2905, 8030, 8031, 8032, 8033 (235 HP)R5019755AAETCALL2024, 2098, 2279, 2280, 2512, 2513, 2514, 2515, 2616, 2617, 2618, 2619, 2660, 2661, 2662, 2663 (235 & 215 HP)R5016374AAETBDDX2175 (EPA 215 HP M/T)R3040141ABDG72174 (EPA 180 HP A/T)R3040143ABDDX1863, 2308 (CAL 180 HP M/T) - with EGRR3040142ABDG71863, 2308 (CAL 180 HP A/T) - with EGRR3040144ABDDX2023, 2175 (215 HP M/T)R4864332DG72022, 2174 (180 HP A/T)R4864331DDX1549, 1815, 1959, 1968 (175 HP M/T)R4711581DG71550, 1816 (160 HP A/T)R47115802002-20012000-1998.55.9L5.9LComplete Engine 9945.9LETBETBETB1993-1991.55.9LETBALL1351, 1579 (160 HP)R47115791991-19895.9LETAALL804 (160 HP)R4429018Transmission Sales Codes: DEE NVG5600 Manual 6-speed; DEG G56 Manual 6-speed w/Dual Mass Flywheel; DG8 48RE 4-speed Automatic144/diesel products/www.mopar.comNote: The photo shown on this page may not be representative of the actual part.

S HORT B L O CK E N G I N E Skit contains: Cylinder BlockCrankshaft and GearConnecting RodsMain, Thrust and Rod Bearing SetPiston and RingsCamshaft Bushings (camshaft not included)Block Hardware Kitcummins-diesel applicationsModel YearApplicationEngineTransEngine CPLReman Part No.Short Block Assemblies2008-20076.7LETJALL1257, 1264, 2885, 8232, 8230, 8231, 8233, 8234R8003549AA2008-2004.55.9LETHDEG, DG81000, 1083, 1091, 1095, 8344, 8345, 8346, 8347, 8348, 8349, 8350, 8351, 8421, 8422, 8423, 8424 (325 HP)Not for use on Megacab 4X4 w/Auto Trans and 2004.5 is designated by Sales Code XCKR8001620AA2007-2006*5.9LETHDG81000, 1083, 8344, 8345 (325 HP)For use only on Megacab 4X4 w/Auto TransR8001621AA2004-20035.9LETHDG8, DEE2998, 8213, 8228 (305 HP)R5093539AAETCAll2624, 8212, 8218, 8223, 8224, 8226, 8410, 8412 (250 & 235 HP)R5093537AAETHDEE2415, 2495, 2906, 2907, 8034, 8035 (245 HP M/T)R5019754AAETCDG7, DDX2496, 2497, 2865, 2866, 2902, 2903, 2904, 2905, 8030, 8031, 8032, 8033 (235 4, 2098, 2279, 2280, 2512, 2513, 2514, 2515, 2616, 2617, 2618, 2619, 2660, 2661, 2662, 2663 (235 & 215 HP)R5015092AA1998-19965.9LETBDDX2023, 2175 (215 HP)R4864330DG71863, 2022, 2174, 2308 (180 HP)R48643291995-19945.9LETBALL1549, 1550, 1815, 1816, 1959, 1968 (175 & 160 HP)R47613681993-1991.55.9LETBALL1579, 1351 (160 HP)R47131691991-19895.9LETAALL804 (160 HP)R4429255*Mega Cab with Auto Trans.Transmission Sales Codes: DEE NVG5600 Manual 6-speed; DEG G56 Manual 6-speed w/Dual Mass Flywheel; DG8 48RE 4-speed AutomaticC onne c t i n g r od skit contains: Connecting Rod Rod Bushing (1 set) Rod Boltscummins-diesel applicationsMODEL YEARAPPLICATION ENGINE CPLREMAN PART NO.2003.5-1998.55.9L2024, 2098, 2279, 2280, 2415, 2495, 2496, 2497, 2512, 2513, 2514, 2515, 2616, 2617, 2618, 2619,2660, 2661, 2662, 2663, 2865, 2866, 2902, 2903, 2904, 2905, 2906, 2907, 2998, 8030, 8031, 8032,8033, 8034, 8035, 8212, 8213, 8218, 8223, 8224,8226, 8228, 8624, 98293, 98294, 98329R5003649AA1998-19895.9L804, 1351, 1549, 1550, 1579, 1815, 1816, 1863, 1959, 2022, 2023, 2174, 2175, 2308(all 12-valve engines)R4761457Note: The photos shown on this page may not be representative of the actual part.www.mopar.com/diesel products/145

CRANKSH A F T Skit contains: Crankshaft Crankshaft Gear Dowel Pin Main, Thrust and Rod Bearings (1 set)cummins-diesel applicationsMODEL YEARAPPLICATIONENGINE CPLREMAN PART NO.2005-20035.9L2624, 2998, 8128, 8212, 8213, 8223, 8224, 8226, 8228, 8229, 8344, 8345, 8346, 8347, 8348, 8349,8350, 8351, 8410, 8411, 8412, 8413, 8421, 8422, 8423, 8424, 98293, 98294, 98329R5086725AA2002-20015.9L2415, 2495, 2496, 2497, 2865, 2866, 2902, 2903, 2904, 2905, 2906, 2907, 8030, 8031, 8032, 8033,8034, 8035R44296321998-19895.9L804, 1351, 1549, 1550, 1579, 1815, 1816, 1863, 1959, 2022, 2023, 2174, 2175, 2308 (all 12-valveengines)R4429632Cylinder h e a d skit contains: C ylinder Head (excludes head gasket) Valves Springscummins-diesel applicationsMODEL YEARAPPLICATIONENGINE CPLREMAN PART NO.2008-20076.7L (Pickup)8230, 8231, 8233, 8234R8027066AA2008-20076.7L (Chassis Cab)1257, 1264, 2885, 8232R8003404AB2008-20065.9L8344, 8345, 8348, 8349, 1000, 1083, 1091, 1095R5179792AA2005-2004.55.9L8212, 8213, 8226, 8228, 8344, 8345, 8346, 8347, 8348, 8349, 8350, 8351, 8410, 8412, 8421, 8422,8423, 8424R5135783AA2004-20035.9L2426, 2998, 8128, 8212, 8213, 8223, 8224, 8226, 8228, 8229, 8410, 8411, 8412, 8413, 98293,98294, 98329R5086860AA2002-1998.55.9L2024, 2098, 2279, 2280, 2496, 2497, 2415, 2495, 2512, 2513, 2514, 2515, 2616, 2617, 2618,2619, 2660, 2661, 2662, 2663, 2865, 2866, 2902, 2903, 2904, 2905, 2906, 2907, 8030, 8031,8032, 8033, 8034, 8035R5014202AA1998-1991.55.9L1351, 1549, 1550, 1579, 1815, 1816, 1863, 1959, 1968, 2022, 2023, 2174, 2175, 2308R5014749AB1991-19895.9L804 (7 mm head replaces 9 mm head — requires 7 mm injectors)R4797177146/diesel products/www.mopar.comNote: The photos shown on this page may not be representative of the actual part.

TURBOC H ARGERSkit contains: Turbocharger Exhaust Flange Gasket Oil Line Gasketscummins-diesel applicationsMODEL YEARAPPLICATIONENGINE CPLREMAN PART NO.2008-20076.7L1257, 1264, 2885, 8230, 8231, 8232, 8233, 8234R8013095AA2008-2004.55.9L1000, 1083, 1091, 1095, 8212, 8213, 8226, 8228, 8344, 8345, 8346, 8347, 8348, 8349, 8350, 8351, 8410,8412, 8421, 8422, 8423, 8424R5143256AA2004-20035.9L2426, 2998, 8128, 8212, 8213, 8223, 8224, 8226, 8228, 8229, 8410, 8411, 8412, 8413, 98293, 98294,98329R5086863AB2002-20005.9L2415, 2495, 2496, 2497, 2662, 2663, 2904, 2905, 2906, 2907, 8032, 8033, 8034, 8035 (235 HP M/T)R5017509AA2000-19995.9L2616, 2617, 2618, 2619, 2660, 2661 (A/T)R5014203AA1998.55.9L2024, 2098, 2279, 2280, 2512, 2513, 2514, 2515R5010961AA1998-1996.55.9L1863, 2308 (CARB)R5010280AA1998-19965.9L2023, 2175 (M/T)R5010278AA1998-19945.9L1816, 1968, 2022, 2174R5010276AA1995-19945.9L1549, 1550, 1815, 1959R5010960AA1993-1991.55.9L1351, 1579R47287001991-19895.9L804R4728036water pu mpskit contains: Water Pump Gasketcummins-diesel applicationsMODEL YEARAPPLICATIONENGINE CPLREMAN PART NO.2008-20076.7L1257, 1264, 2885, 8230, 8231, 8232, 8233, 8234R8003402AA2008-20035.9L1000, 1083, 1091, 1095, 2624, 2998, 8128, 8212, 8213, 8223, 8224, 8226, 8228, 8229, 8344, 8345, 8346,8347, 8348, 8349, 8350, 8351, 8410, 8411, 8412, 8413, 8421, 8422, 8423, 8424, 98293, 98294, 98329R5086959AA2002-1998.55.9L2024, 2098, 2279, 2280, 2415, 2495, 2496, 2497, 2512, 2513, 2514, 2515, 2616, 2617, 2618, 2619, 2660,2661, 2662, 2663, 2865, 2866, 2902, 2903, 2904, 2905, 2906, 2907, 8030, 8031, 8032, 8033, 8034, 8035(all 24-valve engines)R5010964AA1998-19895.9L804, 1351, 1549, 1550, 1579, 1815, 1816, 1863, 1959, 1968, 2022, 2023, 2174R5003665AANote: The photos shown on this page may not be representative of the actual part.www.mopar.com/diesel products/147

FUEL INJECTOR skit contains: FuelInjector Copper Banjo Seal Copper Sealing Washer Copper 7 mm to 9 mm Adapter Sleeve (where applicable)cummins-diesel applicationsMODEL YEARAPPLICATIONENGINE CPLO.E. PART NO.REMAN PART NO.2008-20076.7L8230, 8231, 8233, 823468027067AAR8027067AA2008-20076.7L1257, 1264, 2885, 823267002012ABR8002012AB2006-2004.55.9L8212, 8213, 8226, 8228, 8344, 8345, 8346, 8347, 8348, 8349, 8350, 8351, 8410,8412, 8421, 8422, 8423, 842405135790ADR5135790AD2004-20035.9L2426, 2998, 8128, 8212, 8213, 8223, 8224, 8226, 8228, 8229, 8410, 8411, 8412,8413, 98293, 98294, 9832908004082AAR8004082AA2002-1998.55.9L2024, 2279, 2415, 2495, 2496, 2497, 2512, 2514, 2616, 2618, 2662, 2663, 2865,2866, 2902, 2903, 2904, 2905, 2906, 2907, 8030, 8031, 8032, 8033, 8034, 8035(235 HP)05013847AAR5013847AA2098, 2280, 2513, 2515, 2617, 2619, 2660, 2661 (215 HP)05013848AAR5013848AA1998-19965.9L2023, 2175 (215 HP)N/AR48643281995-19945.9L1550, 1816 (175 HP)N/AR47615951549, 1815, 1959, 1968 (160 HP)04761596R47615961993-1991.55.9L1351, 1579 (160 HP)04638651R46386511991-19895.9L804 (7mm injector tip — supersedes 9mm injector)04720540R4720540STARTERSkit contains: New Brushes and Holders New Battery Posts, Copper Field Coilsand Noise Reduction Pads New Pinion Assembly New Solenoid Switch New Over-running Clutchcummins-diesel applicationsMODEL YEARAPPLICATIONENGINE CPL2002-19945.9L1549,1550, 1815, 1816, 1863, 1959, 2022, 2023, 2174, 2175, 2308, 2024, 2098, 2279, 2280, 2512, 2513, R47410122514, 2515, 2516, 2517, 2518, 2519, 2616, 2617, 2618, 2619, 2660, 2661, 2662, 2663, 2415, 2495,2496, 2497, 2865, 2866, 2902, 2903, 2904, 2905, 2906, 8030, 8031, 8032, 8033, 8034, 80351993-19895.9L804, 1351, 1579148/diesel products/www.mopar.comREMAN PART NO.R4428221ABNote: The photos shown on this page may not be representative of the actual part.

Fuel i n j e ct i o n pu m p skit contains: F uel Pump (complete assembly) Mounting Gasketcummins-diesel applicationsMODEL YEARAPPLICATIONENGINE CPLREMAN PART NO.2008-20076.7L1257, 1264, 2885, 8230, 8231, 8232, 8233, 8234R8027022AA2008-20035.9L1000, 1083, 1091, 1095, 8344, 8345, 8346, 8347, 8348, 8349, 8350, 8351, 8421, 8422, 8423, 8424, 2624,2998, 8128, 8212, 8213, 8223, 8224, 8226, 8228, 8229, 8410, 8411, 8412, 8413, 98293, 98294, 98329R5143425AA20025.9L8034, 8035 (245 HP)R5019657AD2002-20015.9L2660, 2661, 2662, 2663, 2496, 2497, 2865, 2866, 2902, 2903, 2904, 2905, 8030, 8031, 8032, 8033 (235 HP)R5019658AD2001-20005.9L2415, 2495 2906, 2907 (245 HP M/T)R5019657AC2000-19985.9L2024, 2098, 2279, 2280, 2512, 2513, 2514, 2515, 2616, 2617, 2618, 2619 (235 HP)R5013925AA1998-19975.9L2175 (EPA 215 HP M/T)R4883974AA2174 (EPA 180 HP A/T)R4883973AA1998-1996.55.9L1863, 2308 (CARB 180 HP)R4883975AA19965.9L2022 (160 HP A/T)R48824801995-19945.9L1550, 1816 (175 HP M/T)R47613671549, 1815, 1959, 1968 (160 HP A/T)R47985481993-1991.55.9L1351, 1579 (160 HP)R47287451991-19895.9L804 (160 HP)R4429991egr valve kitkit contains: EGR Valve EGR Valve Gasketcummins-diesel applicationsMODEL YEARAPPLICATIONENGINE CPLREMAN PART NO.2008-20076.7L1257, 1264, 2885, 8230, 8231, 8232, 8233, 8234R8026995AANote: The photo shown on this page may not be representative of the actual part.www.mopar.com/diesel products/149

ENGINE CONTROLLERS (J TEC )product features: E ngine controller for Jeep vehicles,Truck and Viper Contains OBDII emissions diagnostic system Reflash capability for easy software upgradesusing DRBIII Each unit is tested to meet O.E. specificationsusing the same series of tests as new parts Faulty components are replaced with new Unit fully resealedcummins–Diesel APPLICATIONSMODEL YEARapplicationEngine cplO.E. PART NO.REMANPART NO.O.E. GENERICPART NO.GENERICPART NO.2008-20076.7L(Chassis Caband Pickup)1257, 1264, 2885, 8232, 8230, 8231,8233, 0065.9L8344, 8345, 8348, 8349, 1000, 1083,1091, 003—8218, 8224, 2624, 8223, 8212, 8213,8226, 8228, 8344, 8345, 8346, 8347,8348, 8349, 8350, 8351, 8410, 8412,8421, 8422, 8423, 2426, 2998, 8128,8212, 8213, 8224, 8229, 8411, 8413,98293, 98294, 98329N/AN/A05191829AAR5191829AA2002—8030, 8031, 8032, 8033, 8034, 8035N/AN/A05083997AAR5083997AA2001*—2415 (EPA 245 HP M/T)333032305JR33032305J05083997AAR5083997AA2495 (CARB 24 HP M/T)373930304JR73930304J05083997AAR5083997AA2496 (EPA 235 HP M/T)333033306JR33033306J05083997AAR5083997AA2497 (CARB 235 HP M/T)373931305JR73931305J05083997AAR5083997AA2865 (EPA 235 HP A/T)333030307JR33030307J05083997AAR5083997AA2866 (CARB 235 HP A/T)373932306JR73932306J05083997AAR5083997AA*Early production sold first half of 2000.Note: All are approved for new-vehicle warranty usage.150/diesel products/www.mopar.comNote: The photo shown on this page may not be representative of the actual part.

ENGINE CONTROLLERS (J TEC )cummins–Diesel APPLICATIONS (cont.)MODEL YEARapplicationEngine cplO.E. PART NO.REMANPART NO.O.E. GENERICPART NO.GENERICPART NO.2001—2902 (EPA 235 HP A/T)383237303JR83237303J05083997AAR5083997AA2903 (CARB 235 HP A/T)383238303JR83238303J05083997AAR5083997AA2904 (EPA 235 HP M/T)383239302JR83239302J05083997AAR5083997AA2905 (CARB 235 HP M/T)383330302JR83330302J05083997AAR5083997AA2906 (EPA 245 HP M/T)383331302JR83331302J05083997AAR5083997AA2907 (CARB 245 HP M/T)383332302JR83332302J05083997AAR5083997AA2660 (EPA 215 HP A/T)353339304JR53339304J05083997AAR5083997AA2661 (CARB 215 HP A/T)353430304JR53430304J05083997AAR5083997AA2662 (EPA 235 HP M/T)353431304JR53431304J05083997AAR5083997AA2663 (CARB 235 HP M/T)353432304JR53432304J05083997AAR5083997AA2516, 2616 (EPA 235 HP M/T)323639306JR23639306JN/AR5083996AA2517, 2617 (EPA 215 HP A/T)323730306JR23730306JN/AR5083996AA2518, 2618 (CARB 235 HP M/T)323638306JR23638306JN/AR5083996AA2519, 2619 (CARB 215 HP A/T)323637306JR23637306JN/AR5083996AA2024, 2515 (EPA 235 HP M/T)N/AR33036304JN/AR5083996AA2098, 2513 (EPA 215 HP A/T)N/AR33037304JN/AR5083996AA2279, 2514 (CARB 235 HP M/T)N/AR33034304JN/AR5083996AA2280, 2515 (CARB 215 HP —*Early production sold first half of 2000.Note: All are approved for new-vehicle warranty usage.www.mopar.com/diesel products/151

vacuum PU M PSkit contains: New Seals, O-rings and ImpellersCUMMINS-diesel applicationsMODEL YEAREngine CPLREMAN PART NO.2002-1991AllR5019734AA152/diesel products/www.mopar.comNote: The photo shown on this page may not be representative of the actual part.

FUELSYSTEMSELECTRIC FUEL PUMPSwww.mopar.com/diesel products/153

140 / diesel products / www.mopar.com the Mopar advantage Diesel engines anD parts cylinder head assembly — Mopar will still remanufacture the cylinder heads when a complete engine replacement isn't necessary. Mopar Diesel In-Line, 6-cylinder heads use original equipment components and meet strict original equipment engineering standards.

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