Body On

Engine - Body On





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 can be removed, refer to Engine - Body Off Body Off.

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.

NOTE: For EXPORT ONLY vehicles (outside US/Canada), an Export Supplement is provided and should be referenced to identify differences that can impact service procedures. Vehicles can be identified by referring to the underhood Vehicle Emission Control Information (VECI) label which states, "Not certified for US EPA or CARB Regulations."

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

2. Remove the cooling module. For additional information, refer to Engine Cooling - Diesel Engine Cooling Module.

3. 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.

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





5. NOTE: The wiring harness bracket bolt is hidden behind the serpentine belt.

Remove the cooling fan clutch wiring harness bracket bolt.

- Disconnect the cooling fan clutch electrical connector.





6. NOTE: The fan clutch has RH threads.

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





7. Release the clip and disconnect the Charge Air Cooler (CAC) inlet tube from the turbocharger.





8. Disconnect the 2 coolant hoses from the CAC.





9. Release the clip and disconnect the CAC outlet tube from the Throttle Body (TB) throttle body.
- Disconnect the Charge Air Cooler Temperature (CACT) sensor.





10. Remove the LH battery. For additional information, refer to Battery, Mounting and Cables Battery and Battery Tray.

11. Remove the 2 CAC cooler mounting bolts and the CAC.





12. Using a suitable suction device, drain the power steering fluid reservoir.

13. Remove the power steering pressure tube bolt and disconnect the power steering pressure tube from the power steering pump.
- Remove and discard the 2 O-rings from the power steering pressure tube.





14. Disconnect the power steering return hose from the power steering pump.





15. Disconnect the wiring harness retainer from the LH battery tray.





16. Disconnect the 2 coolant hoses from the coolant reservoir.





17. Remove the 4 bolts and the LH battery tray assembly.





18. Release the clip and remove the upper radiator hose.





19. 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.





20. Disconnect the lower radiator hose retainers from the lower radiator support.





21. Release the clip and separate the lower radiator hose sections.





22. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
- 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 openings on rocker covers, and lower intake.

Remove the 15 bolts and the upper intake manifold.

- Remove and discard the upper intake manifold gaskets.





25. Disconnect the TB electrical connector.





26. Disconnect the Exhaust Gas Recirculation Temperature (EGRT) electrical connector.
- Disconnect the EGRT wiring harness retainer.





27. NOTE: The 2 upper bolts are shown, the 2 lower bolts are similar.

Remove the 4 bolts and the Exhaust Gas Recirculation (EGR) outlet pipe.

- Remove and discard the EGR outlet pipe gaskets.





28. Loosen the 4 turbocharger inlet boot clamps.





29. NOTE: The oil separator hose contains a collar at the lower intake manifold fitting. Rotate the collar counterclockwise to release the hose.

Disconnect the oil separator hose from the lower intake manifold.





30. Remove the 3 bolts and the lower intake manifold.





31. 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 turbocharger coolant outlet tube from the turbocharger.





32. Remove and discard the 3 nuts from the RH turbocharger inlet pipe.





33. Position the Exhaust Pressure (EP) sensor electrical connector heat shield aside.
- Disconnect the EP sensor electrical connector.





34. Loosen the RH turbocharger inlet pipe clamp and remove the RH turbocharger inlet pipe.
- Remove and discard the turbocharger inlet pipe gasket and clamp.





35. Loosen the turbocharger downpipe clamp.





36. Remove the RH fender splash shield. For additional information, refer to Front End Body Panels Fender Splash Shield.

37. Remove the turbocharger downpipe bracket bolt.





38. Remove the 2 bolts from the turbocharger downpipe flange and remove the turbocharger downpipe.
- Remove and discard the turbocharger downpipe clamp.





39. Remove and discard the 3 nuts from the LH turbocharger inlet pipe.





40. Loosen the LH turbocharger inlet pipe clamp, and remove the LH turbocharger inlet pipe.
- Remove and discard the turbocharger inlet pipe gasket and clamp.





41. Remove the 2 heater core inlet tube bolts.
- Disconnect the heater core inlet tube fitting.

- Remove the heater core inlet tube.

- Remove and discard the O-ring from the heater core inlet tube.





42. Position the wiring harness heat shield aside and disconnect the turbocharger actuator electrical connector.





43. 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.





44. NOTE: Lift the turbocharger off of the locating dowels before removal.

NOTE: The turbocharger is a tight fit between the cowl and the injection pump-to-high pressure fuel rail lines. Removing the injection pump-to-high pressure fuel rail lines is not necessary.

Remove the turbocharger from the engine.

- Remove and discard the turbocharger mounting gasket.

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





46. If equipped, disconnect the block heater cord.





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

48. 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.





49. Remove and discard the 8 torque converter nuts.





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





51. NOTICE: Failure to replace the engine support insulator nuts may result in engine support insulator damage.

Remove and discard the 3 LH engine support insulator nuts.





52. NOTICE: Failure to replace the engine support insulator nuts may result in engine support insulator damage.

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

Remove and discard the 4 RH engine support insulator nuts.





53. 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.





54. Remove the 9 transmission bellhousing bolts.





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

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





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

Install the engine oil drain plug.





57. Remove and discard the engine oil filter.

58. Remove the 15 bolts and the lower engine oil pan.
- Remove and discard the lower engine oil pan gasket.





59. Remove the EGR cooler. For additional information, refer to Engine Emission Control Exhaust Gas Recirculation (EGR) Cooler.

60. Remove the nut from the evaporator-to-compressor suction tube fitting and disconnect the tube.
- Remove and discard the O-ring seals and gaskets.

- Plug or cap the opening as needed.





61. Remove the crankcase vent oil separator. For additional information, refer to Engine Emission Control Service and Repair.

62. Disconnect the 3 PCM electrical connectors and the wiring harness retainers.





63. Remove the 2 PCM bracket nuts, the bracket, and the PCM.





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





65. Remove the power distribution cover.





66. Remove the 2 positive power distribution cable nuts and position the 2 cables aside.





67. Disconnect the RH positive battery cable clamp.
- Disconnect the 2 battery cable retainers.





68. If equipped, disconnect the secondary generator electrical connector at the front of the RH battery tray.





69. Disconnect the 2 engine wiring harness electrical connectors at the rear of the RH battery tray.





70. Remove the 3 ground strap bolts from the RH side of the firewall.





71. Remove the ground strap bolt from the LH side of the cowl.





72. NOTE: Transmission removed for clarity.

Remove the engine oil level indicator tube from the engine.

- Remove and discard the 2 O-rings from the engine oil level indicator tube.





73. Position a transmission jack and support the transmission.

74. Remove the 2 upper transmission bellhousing bolts.





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





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





77. 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.





78. NOTICE: During removal of the engine, the engine oil cooler will pass very close to the frame crossmember. Remove the engine slowly, continually checking to make sure the engine oil cooler does not hit the frame crossmember, or component damage may occur.

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.

Raise and remove the engine from the vehicle.