Steps 1-40

Engine - Body On









Removal

All vehicles

NOTE: It is recommended that this component be serviced with the vehicle body removed. If the body can be removed, refer to Engine - Body Off Engine - Removal - Body Off.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Vehicle Jacking and Lifting.

2. Disconnect the LH and RH battery ground cables. For additional information, refer to Battery.

3. Release the fuel pressure. For additional information, refer to Fuel Delivery and Air Induction.

Vehicles with manual transmission

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

Remove the transmission.

5. Remove the clutch disc and pressure plate. For additional information, refer to Clutch, M/T.

All vehicles

6. Remove the cooling module. For additional information, refer to Cooling System &/or Engine Block Heater.

7. Remove the oil pan drain plug and drain the engine oil.





8. Install the oil pan drain plug.
- Tighten to 44 Nm (32 lb-ft).





9. Loosen the 2 bolts for the turbocharger downpipe.





10. Remove the bolt and washer for the EGR-Oxidation Catalytic Converter (OC) pipe bracket.
- Discard the bolt.





11. Remove the bolt, washers and bracket for the EGR-OC pipe bracket.
- Discard the bolt.





12. Disconnect the fog light electrical connector and pin-type retainer.





13. NOTE: RH side shown, LH side similar.

Mark the location of the bumper. Remove the 6 bolts and the front bumper.





14. Remove the 2 bolts for the fuel cooling pump.





15. Disconnect the 7 retainers and remove the lower cooling fan shroud.





16. Disconnect the front impact severity sensor electrical connector. Remove the bolt and the front impact severity sensor.





17. Loosen the clamp and remove the LH Charge Air Cooler (CAC) tube.





18. Disconnect the cooling fan electrical connector. Carefully squeeze the locking tabs and remove the cooling fan electrical connector from the stator.





19. NOTE: The cooling fan has LH threads.

Using the Fan Clutch Nut Wrench and Fan Hub Nut Wrench, remove the cooling fan assembly.





20. Remove the 2 nuts, 2 bolts and the cooling fan stator.





21. NOTE: Single generator shown, dual generator similar.

Remove the accessory drive belt.





Vehicles with A/C

22. Remove the A/C drive belt.
- Remove the belt from the bottom of the A/C pulley then remove the belt from the crankshaft pulley.





All vehicles

23. Remove the retaining nut for the power steering hose and tube.





24. NOTE: When positioning the pump aside, raise the supply tube up to clear the Engine Coolant Temperature (ECT) sensor connector.

Remove the 3 bolts for the power steering pump. Position the power steering pump aside.





25. If equipped with dual generators, position the wiring boot and remove the nut from the generator wiring. Disconnect the generator electrical connector.





26. Position the wiring boot and remove the nut from the generator wiring. Disconnect the generator electrical connector.





27. Disconnect the pushpin and position the generator wiring aside.





28. Remove the bolt and the accessory drive belt idler pulley.





29. Remove the 2 nuts, 2 bolts and the Front End Accessory Drive (FEAD) assembly.





30. Remove the bolt for the RH ground cable. Remove the 2 stator stand offs.





Vehicles with A/C

31. Disconnect the A/C clutch electrical connector and wire retainer.





32. Remove the 2 retaining nuts and the A/C hoses.
- Remove and discard the O-ring seals and gaskets.

- Plug or cap the opening as needed.





33. Remove the 3 bolts and the A/C compressor.





34. Disconnect the A/C pressure switch electrical connector. Disconnect the A/C line from the clip and remove.





All vehicles

35. Remove the retaining nut and disconnect the transmission cooler tubes from the engine.





36. NOTE: Cover positioned aside for clarity.

Remove the retaining nut and disconnect the pushpin retainer for the power supply cable. Position the cable on the engine.





37. Remove the hold-down bolt and the LH battery.





38. Disconnect the EGR cooler-to-degas bottle hose. If equipped, disconnect the vacuum hose.





39. Disconnect the engine fill hose from the degas bottle.





40. Remove the 4 bolts and the degas bottle module.