Removal

Engine





Special Tool(s)

Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the LH and RH battery ground cables.

Vehicles with manual transmission

3. NOTE: On vehicles equipped with manual transmissions, the transmission must be removed before the engine can be removed.

Remove the transmission.
4. Remove the clutch.

All vehicles
5. Remove the air cleaner assembly.
6. Remove the radiator.
7. Remove the charge air cooler.

Vehicles with A/C
8. Remove the A/C condenser assembly.

All vehicles
9. Remove the parking lamp and the headlamp assemblies.
10. Remove the radiator grille, the radiator grille opening panel, and the upper radiator core supports.
11. Remove the front bumper.





12. Disconnect the transmission cooler hoses.





13. Remove the bolts and the transmission oil cooler.





14. Remove the bolts and position the power steering cooler out of the way.
15. Remove the intake manifold.





16. Disconnect the heater hose at the coolant pump.





17. Remove the battery cable cover.





18. Remove the nut and position the cable out of the way.





19. Remove the clips and disconnect the fuel lines.





20. Remove the lower radiator hose clamp and the hose.





21. Remove the power steering upper mounting bolts.





22. NOTE: Bolts need to be removed evenly.

Remove the bolts and position the power steering pump out of the way.





23. Remove the bolt and the left side ground cable.





24. Remove the nut and the battery cable bracket.





25. Remove the ground stud and the ground cable.





26. Disconnect the glow plug electrical connectors.

Vehicles with A/C





27. Disconnect the A/C high pressure switch and the A/C clutch electrical connectors.





28. Disconnect the air conditioning manifold lines from the A/C compressor.





29. Remove the A/C compressor.

All vehicles





30. Disconnect the Crankshaft Position (CKP) sensor electrical connector.

Vehicles with automatic transmission





31. Remove the automatic transmission fluid indicator and tube.

All vehicles





32. Remove the ground strap at the back of the right head.





33. Remove the solenoid cap and disconnect the starter wiring.





34. Disconnect the block heater electrical connector.
35. Position the block heater and starter wiring harness out of the way.

Vehicles with automatic transmission





36. Remove the torque converter cover.





37. Remove the torque converter nuts.

All vehicles





38. NOTE: Left side shown; right side similar.

Remove the bolts for the turbocharger adapter pipe.





39. NOTE: LH shown; RH similar.

Remove the motor mount nuts.





40. Loosen the nuts at the turbocharger adapter pipe flange.

Vehicles with automatic transmission





41. Remove the nine bell housing bolts.

All vehicles





42. Remove the turbocharger adapter pipe.





43. Remove the fuel injection control module mounting bolts for access to the module electrical connectors.





44. Disconnect the electrical connectors and remove the fuel injection control module.





45. Remove the nuts and the fuel injection control module bracket.





46. Remove the left rear valve cover stud.





47. Remove the transmission cooler line bracket.





48. Secure the turbocharger outlet pipe.





49. Remove the manufacturer's lifting eye.





50. Install the engine lifting eye on the RH cylinder head.





51. Install the front lifting brackets.

Vehicles with automatic transmission
52. Position a suitable jack under the transmission.

All vehicles
53. Install the Heavy Duty Floor Crane and Diesel Engine Lifting Bracket on the engine.





54. Raise the engine high enough to clear the No. 1 crossmember and pull the engine forward and clear of the vehicle.