Engine - Removal

REMOVAL





1. Open the hood.
2. Remove the engine cover.
3. Disconnect the hood support struts and position hood out of the way.





4. Disconnect both negative and positive battery cables (1, 3).
5. Remove the intake air box and tube.
6. Raise the vehicle on the hoist.





7. Drain engine coolant Service and Repair.
8. Remove the engine oil drain plug and drain engine oil.
9. Reinstall drain plug. Tighten to 50 Nm (37 ft. lbs.).





10. Remove bolts (1) and the bell housing access cover (2).





11. Install the Barring Tool 7471B (1).




12. Using the Barring Tool 7471B (1), rotate the engine and remove the torque converter bolts.
a. On manual transmission models, remove the dual mass flywheel bolts.
13. Remove the Barring Tool 7471B (1).





14. Remove the bell housing retaining bolts.
15. Remove the left ground strap.
16. Disconnect the transmission wiring harness connector.





17. Remove the transmission collar (1), if equipped and then flywheel housing (2).
18. Remove the transmission to engine bolts.
19. Remove the rack and pinion bolts.
20. Lower the vehicle on the hoist.
21. Recover A/C refrigerant. Refrigerant System Recovery.
22. Remove the upper radiator hose.





23. Remove the coolant recovery bottle hose.
24. Remove the windshield washer hose.
25. Remove the right side air deflector.





26. Remove the A/C lines from the condenser.










27. Remove the charge air hose at the cooler.
28. Remove the charge air hose/condenser bolts.
29. Remove the radiator retaining bolts.
30. Remove the lower radiator hose.
31. Remove the charge air inlet and outlet tubes (4).
32. Remove the charge air cooler (2).
33. Remove the power steering cooler bolts and position the power steering cooler aside.
34. Remove the radiator.
35. Remove the fan shroud mounting bracket (3) and shroud. Cooling Fan - Removal.










36. Remove the cooling (3) and fan drive fan (2).
37. Remove the serpentine drive beltSerpentine Accessory Drive Belt - Removal.





38. Remove the power steering pump bolts and position the power steering pump aside.





39. Disconnect the Air Conditioning pressure switch connector.
40. Remove the radiator lower bracket shroud.
41. Remove the drive belt tensioner.





42. Remove the crankshaft damper.
43. Disconnect the ECM power connector and the engine to vehicle wiring harness connector.





44. Remove the starter cable at the left battery and power distribution center.
45. Remove the starter motor (2) Starter - Removal.
46. Disconnect the intake heater connector.
47. Disconnect the battery negative cables to the engine block on the driver and passenger side.





48. Disconnect the generator feed wire.
49. Disconnect the block heater.
50. Disconnect the left side ground wire.





51. Remove the clamp at the exhaust pipe to the turbocharger outlet elbow connection. Do not remove the elbow (1) from the turbocharger (8).
52. Disconnect the heater core supply and return hoses.
53. Disconnect the injector harness connectors.










54. Automatic transmission models: Disconnect transmission oil cooler lines from in front of radiator using special tool #6931.
55. Remove the radiator upper support panel.
56. Remove the A/C condenser (1).





57. Disconnect the fuel supply and return lines from the fuel filter housing.





58. Disconnect the CCV tube (4) and lube oil drain tube (2) to cylinder head cover (1)
59. Remove the cylinder head cover (1). Cylinder Head Cover(s) - Removal.










60. Disconnect the injector wiring harness connectors to injector connections on cylinder head cover carrier gasket (3).
61. Remove the injector harness nuts to injectors (1).
62. Remove the cylinder head cover/injector wiring gasket (2).





63. Remove the coolant hose at the EGR cooler inlet.
64. Remove the coolant hose at the EGR cooler outlet.
65. Remove the EGR control valve and tube assembly.
66. Remove the EGR cooler.
67. Remove the coolant filter from the cylinder head.










68. Remove the coolant transfer tube retainers and position the coolant transfer tube aside.

NOTE: Extreme care should be used to keep dirt/debris from entering the fuel lines. Plastic caps should be used on the ends of the fuel lines.

NOTE: Mark the location of pushrods and crossheads for reinstallation.

69. Remove the No. 4 rocker arms (1), pedestals (2), and pushrods for cylinders No. 4, No. 5, and No. 6.
70. Remove the No. 5 and No. 6 high pressure fuel lines.
71. Remove the No. 5 and No. 6 fuel injector.
72. Remove the No. 4 and No. 5 head bolts.










73. Install the front and rear engine lift bracket. Tighten to 77 Nm (57 ft. lbs.).
74. Remove the two cylinder head bolts (1 and 3) according to the diagram and install the Engine Lifting Bracket 9009 (2). Tighten bolts to 105 Nm (77 ft. lbs.).
75. Remove the engine mount through bolts and nuts.
76. Attach a chain with two hooks to the engine lift brackets.
77. While keeping engine level, lift straight up out of the mounts.
78. Rotate the nose of engine upward and pull out of chassis.