Steps 1-50
Engine Replacement- Tools Required
- J 36857 Engine Lift Brackets
- J 43181 Quick Connect Connector Removal
Removal Procedure
Important: In order to remove the engine the vehicle needs to be on a hoist. The front tires will also require removal. The vehicle will have to be supported by the frame when the tires are removed.
1. Recover the A/C System.
2. Disconnect the batteries negative cables.
3. Move the hood to the service position by moving the hood hinge bolts (1) to the service positions (2).
4. Remove the upper intake manifold sight shield using the following procedure:
4.1. Remove the retaining bolt in the front of the shield.
4.2. Lift-up on the front of the shield.
4.3. Lift the shield off the rear bracket.
5. Drain the engine coolant and the engine block.
Important: After removing the turbocharger air ducts and hoses, cover the turbocharger openings and the ducts with tape to prevent entry of objects.
6. Remove the air cleaner outlet duct from the air cleaner and the turbocharger.
7. Disconnect the following engine wire harness connectors:
- Mass air flow switch (1)
- Air conditioning pressure cycling switch (2)
- Surge tank switch (6)
8. Remove the engine wire harness clip from the accumulator (3).
9. Remove the engine wire harness clips from the wheelhouse inner panel (4).
10. Remove the engine wire harness clip from the engine bracket (5),
11. Remove the air cleaner assembly and the bracket.
12. Remove the surge tank.
13. Raise the vehicle. Refer to Vehicle Lifting.
14. Support the vehicle and remove both front tires and wheels.
15. Remove both front fender wheelhouse inner panels (1).
16. Lower the vehicle.
17. Remove the charged air cooler pipes and hoses from the engine and the charged air cooler.
18. Loosen the hose clamps and remove the radiator inlet hose from the radiator and the engine.
19. Remove the upper fan shroud.
20. Remove the lower fan shroud.
21. Loosen the hose clamp and remove the radiator outlet hose from the radiator.
22. Disconnect the outlet heater hose from the outlet radiator hose.
23. Remove the hose clips from the frame.
24. Loosen the hose clamp and remove the radiator outlet hose from the engine.
25. Remove the bolt (2) retaining the outlet heater hose pipe to the generator mounting bracket.
26. Remove the nut (1) retaining the outlet heater hose pipe to the fuel filter mounting bracket.
27. Move the heater hose and secure aside.
28. Remove the upper radiator support.
29. Remove the radiator.
30. Remove the charged air cooler.
31. Remove the A/C condenser.
32. Disconnect the following electrical connectors:
- Generator harness connector (1)
- A/C refrigerant switch (3)
- Dual generator harness connector (4), if equipped
- A/C compressor clutch (5)
33. Remove the harness clip (2) from the A/C compressor bracket.
34. Remove the battery cable to the generator.
35. If equipped remove the battery cable to the auxiliary generator.
36. Remove the battery cable harness clip from the bracket.
37. Remove the bolt retaining the battery cable junction block from the power steering pump.
38. Move and secure the battery cables out of the way.
39. Disconnect both fuel injection control module harness connectors. Flip the latch up and it will disconnect the connector.
40. Remove the engine wire harness from the retainer.
41. Disconnect the fuel lines at the engine.
42. Remove the nut and the fuel line bracket from the upper valve rocker arm cover stud.
43. Secure the fuel lines out of the way.
44. Remove the power supply cable from the glow plug relay.
45. Remove the drive belt
46. Disconnect the suction hose from the accumulator. The compressor end can remain on the compressor.
47. Remove the A/C compressor mounting bolts.
48. Move the A/C compressor with the hoses attached to the right side of the engine compartment.
49. Move the wiring harness to the left side of the vehicle and secure out to the way.
50. Remove the bolts retaining the power steering pump front bracket to the power steering pump and the air conditioner compressor mounting bracket.