Body Off

Engine - Body Off





Removal

NOTICE: Change the engine oil any time the turbocharger is removed from the engine. The passages in the block, located underneath the turbocharger, are direct passages to the lubrication system. Debris and/or coolant may enter the lubrication system and engine damage may occur.

NOTE: It is recommended that this component be serviced with the vehicle body removed. If the body cannot be removed, refer to Engine - Body On Body On.

NOTE: During the repair or installation of fuel-related components, cap, tape or otherwise appropriately protect all fuel openings to prevent the ingress of dirt or other contamination. Remove caps, tape and other protective materials prior to installation.

1. Remove the body. For additional information, refer to Full Frame and Body Mounting Body.

2. WARNING: Do not work on the fuel system until the pressure has been released and the engine has cooled. Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure fuel may cause cuts and contact with hot fuel may cause burns. Failure to follow these instructions may result in serious personal injury.

Release the fuel system pressure. For additional information, refer to Fuel System - General Information - Gasoline and Diesel Fuel System Pressure Release.

3. Mark the location of the tires on the floor prior to rolling out the chassis. Roll the chassis out from under the body.

4. NOTICE: Failure to replace the transmission support insulator nuts may result in transmission support insulator damage.

NOTE: If the transmission support insulator stud loosens when the transmission support insulator nut is removed, the stud must be discarded and a new stud installed.

Remove and discard the 2 transmission support insulator nuts.





5. NOTE: The engine oil drain plug is a quarter turn design.

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





6. NOTE: The engine oil drain plug is a quarter turn design.

Install the engine oil drain plug.





7. Remove and discard the engine oil filter.

8. Remove the turbocharger downpipe bracket bolt.





9. Remove the 2 turbocharger downpipe flange bolts.





10. Remove the turbocharger downpipe.
- Remove and discard the turbocharger downpipe clamp.





11. If equipped, disconnect the block heater cord.





12. Remove the starter motor. For additional information, refer to Starting System - Diesel Engine Service and Repair.

13. NOTE: The flexplate access cover retainers are plastic, use care when removing.

Unscrew the 2 flexplate access cover retainers and remove the flexplate access cover.





14. Remove and discard the 8 torque converter nuts.





15. Remove the engine wiring harness bracket bolt and the ground wire bolt.





16. Remove the 4 nuts and the cooling fan stator.





17. Remove the transmission cooler line bracket nut from the RH side of the engine and position the transmission cooler lines aside.





18. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components.

Disconnect the fuel supply tube quick connect coupling from the secondary fuel filter and position aside. For additional information, refer to Fuel System - General Information - Gasoline and Diesel Quick Connect Coupling.

- Disconnect the fuel return tube quick connect coupling from the fuel injection pump return tube. For additional information, refer to Fuel System - General Information - Gasoline and Diesel Quick Connect Coupling.





19. Remove the 2 fuel line bracket bolts from the transmission bellhousing.





20. Remove the 2 fuel line bracket bolts from the left side of the transmission and position the fuel lines aside.





21. NOTE: Only one retainer shown, 3 other retainers similar.

Disconnect the power steering pressure line from the 4 retainers and secure the power steering pressure line to the engine.





22. Disconnect the Manifold Absolute Pressure (MAP) sensor and the turbocharger actuator electrical connectors.
- Disconnect the 2 wiring harness retainers.





23. Remove the engine and transmission oil level indicator tube bolts.
- Disconnect the wastegate vacuum line from the wastegate actuator.





24. NOTE: Cover or tape the openings on the rocker covers and lower intake.

Remove the 15 bolts and the upper intake manifold.

- Remove and discard the intake manifold gaskets.





25. NOTE: Left side shown, right side similar.

Remove and discard the 3 nuts from each turbocharger inlet pipe.





26. NOTE: The Exhaust Pressure (EP) sensor and tube are attached to the RH turbocharger inlet pipe.

Position the EP sensor electrical connector heat shield aside.

- Disconnect the EP sensor electrical connector.





27. NOTE: Left side shown, right side similar.

Loosen the 2 turbocharger inlet pipe clamps and remove the 2 turbocharger inlet pipes.

- Remove and discard the turbocharger inlet pipe gaskets and clamps.





28. Release the clip and remove the Charge Air Cooler (CAC) tube from the turbocharger.





29. NOTE: Use a 3/8 inch Jiffy-tite quick line disconnect tool, such as Snap-on(R) LDTSP4 or equivalent, to disconnect the turbocharger coolant outlet tube.

Disconnect the coolant return tube from the turbocharger.





30. Loosen the 4 turbocharger inlet boot clamps.





31. NOTE: Left side shown, right side similar.

NOTE: The turbocharger mounting bolts are torque-to-yield design and cannot be reused.

Remove and discard the 4 turbocharger mounting bolts.





32. NOTE: Lift the turbocharger off of the locating dowels before positioning rearward for removal.

Remove the turbocharger and the 2 turbocharger inlet boots from the engine.

- Remove and discard the turbocharger mounting gasket.

33. Install the Engine Removal Bracket and the 4 bolts.
- Tighten to 55 Nm (41 lb-ft).





34. Remove the upper Front End Accessory Drive (FEAD) bracket mounting bolt.





35. Install the Lifting Eye and the upper FEAD bracket mounting bolt.
- Tighten to 24 Nm (18 lb-ft).





36. Position a Heavy Duty Floor Crane and connect to the Engine Removal Bracket.
- Install a suitable ratchet strap from the arm of the Heavy Duty Floor Crane to the Engine Lifting Bracket to adjust the angle of the engine.





37. NOTICE: Failure to replace the engine support insulator cross bolts may result in engine support insulator damage.

NOTE: If it is necessary to loosen the engine support insulator nuts, they must be discarded. For additional information, refer to Engine Support Insulators Removal and Replacement.

Remove and discard the 2 engine support insulator cross bolts.





38. Lift the engine and transmission assembly high enough to clear the engine support insulators and support the transmission using a suitable transmission jack.

39. Remove the 4 lower transmission-to-engine mounting bolts.





40. Remove the 5 upper transmission-to-engine mounting bolts.





41. NOTICE: After the engine is removed, position the engine close to the floor in case of lifting crane failure. Failure to lower the engine may result in engine damage.

Remove the engine from the vehicle.