Removal
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 cable.
3. Remove the cooling fan stator.
4. Remove the air cleaner assembly and the charge air cooler.
Vehicles with A/C
5. Remove the A/C condenser assembly.
All vehicles
6. Remove the radiator grille opening panel reinforcement.
7. Remove the nut and position the body feed cable aside.
8. Remove the bolts and the upper radiator support.
9. Remove the front bumper.
^ Remove the rear supporting bolts (one on each side).
^ Remove the front bolts (two each side).
10. Remove the bolts and position the power steering cooler aside.
11. Disconnect the transmission cooler hoses.
12. Remove the bolts and the transmission cooler.
13. Remove the intake manifold.
14. Remove the nuts and the fuel injection control module brackets.
15. Remove the bolts and battery tray.
16. Disconnect the Powertrain Control Module (PCM) electrical connector.
17. Disconnect the 12-pin and 8-pin electrical connectors.
18. Disconnect the Camshaft Position (CMP) sensor electrical connector and position the engine wiring harness aside.
19. Disconnect the LH glow plug electrical connector.
20. Remove the lower radiator hose.
21. Disconnect the heater hose at the front cover.
22. Remove the clips and disconnect the fuel lines.
23. NOTE: Only one stand-off shown.
Remove the stator stand-off.
24. Remove the power steering pump upper mounting bolts.
25. Remove the bolts and position the power steering pump aside.
26. Remove the nut and the battery cable bracket.
27. Remove the ground stud and ground cable.
28. Disconnect the push pin retainer and injection control pressure (ICP) electrical connector. Disconnect the glow plug module electrical connectors.
29. Disconnect the wire retainers.
30. Remove the retaining nuts and the glow plug control module and mounting bracket.
31. Disconnect the Injection Control Pressure (ICP) sensor electrical connector.
32. NOTE: Only one retainer shown.
Disconnect the wire retainers from the valve cover studs.
33. Disconnect the RH glow plug electrical connector.
Vehicles with A/C
34. Disconnect the A/C high-pressure switch and A/C clutch electrical connectors.
35. Remove the retaining nut and disconnect the A/C hose.
^ Remove and discard the O-ring seal.
^ Plug or cap the openings.
36. Remove the bolt and the A/C compressor.
All vehicles
37. Disconnect the Crankshaft Position (CKP) sensor electrical connector and position the wiring aside.
38. Remove the retaining nut. Remove the automatic transmission fluid indicator and tube.
39. Remove the ground strap at the back of the right head.
40. Remove the solenoid cap and disconnect the starter wiring.
41. If equipped, disconnect the block heater cord.
42. Remove the torque converter cover.
43. Remove and discard the torque converter nuts.
44. NOTE: LH shown, RH similar.
Remove the bolts for the turbocharger adapter pipe.
45. NOTE: LH shown, RH similar.
Remove the motor mount nuts.
46. Drain the engine oil.
47. Loosen the nuts at the turbocharger adapter pipe flange.
48. Remove the nine bellhousing bolts.
49. Remove the turbocharger adapter pipe.
50. Remove the left rear valve cover stud.
51. Position the block heater cord and starter wiring aside.
52. Remove the transmission cooler line bracket.
53. Secure the turbocharger outlet pipe.
54. Remove the manufacturer's lifting eye.
55. Install the lifting eye on the RH cylinder head.
56. Install the front lifting brackets.
57. Position a suitable jack under the transmission.
58. Install the heavy duty floor crane and diesel engine lifting bracket on the engine.
59. Raise the engine high enough to clear the No. 1 crossmember and pull the engine forward and clear of the vehicle.
60. Remove the engine lifting equipment from the engine.