Removal and Replacement
REMOVAL - ENGINE1. Disconnect both battery negative cables.
2. Disconnect engine grid heater harness at grid heater relays.
3. Disconnect electrical connections from rear of alternator.
4. Recover A/C refrigerant.
5. Raise vehicle on a hoist.
6. Drain engine coolant.
7. Remove engine oil drain plug and drain engine oil.
8. Reinstall drain plug. Tighten to 50 Nm (37 ft. lbs.) torque.
9. Lower the vehicle.
10. Remove fan (3) and fan drive (2).
11. Remove fan shroud mounting bracket (3) and shroud.
12. Remove radiator upper hose.
13. Disconnect the coolant recovery bottle hose from the radiator fill neck.
14. Disconnect heater core supply and return hoses from the cylinder head fitting and coolant pipe.
15. Raise vehicle on a hoist.
16. Remove transmission and transfer case (if equipped).
17. Disconnect exhaust pipe from turbocharger extension pipe.
18. Disconnect engine harness to vehicle harness connectors.
19. Remove starter motor (2).
20. Remove flywheel/flexplate.
21. Remove transmission adapter.
22. Disconnect A/C suction/discharge hose from the rear of the A/C compressor.
23. Lower vehicle.
24. Disconnect lower radiator hose from radiator outlet.
25. Automatic transmission models:
26. Disconnect transmission oil cooler lines from in front of radiator using special tool #6931.
27. Remove radiator.
28. If A/C equipped, disconnect A/C condenser refrigerant lines.
29. Disconnect charge air cooler piping.
30. Remove charge air cooler mounting bolts (1).
31. Remove charge air cooler (2) from vehicle.
32. Remove the A/C condenser (1).
33. Remove damper and speed indicator ring from front of engine.
34. Remove lower fan shroud bracket (3) from engine.
35. Remove upper fan shroud brackets from engine.
36. Disconnect engine block heater connector.
37. Disconnect A/C compressor and pressure sensor electrical connectors.
38. Remove the passenger battery ground cable from the engine block. Remove the driver side battery ground cable from the engine block.
39. Remove power steering pump from engine by removing 3 bolts.
40. Disconnect the ECM power connector.
41. Disconnect the ECM ground wire from the hydroform screw.
42. Disconnect the fuel supply and return hoses.
NOTE: For early builds, Ensure that grounding spring (3) remains intact with cylinder head cover (2).
43. FOR EARLY BUILDS Remove the cylinder head cover (2)and grounding spring (3).
44. FOR EARLY BUILDS Disconnect the 3 injector harness connectors at the rocker housing. Disconnect the wire harnesses from the injectors.
45. FOR LATE BUILDS Remove the cylinder head cover (1).
46. FOR LATE BUILDS Disconnect the wire harnesses from the injectors (3).
47. FOR LATE BUILDS Remove the cylinder head cover carrier gasket (2).
48. Loosen #6 fuel line shield bolts and rotate shield out of the way.
49. Remove cylinder #5 and #6 high pressure fuel lines.
50. Remove the rear engine lift bracket.
51. Remove cylinder #4, #5, and #6 intake and exhaust rocker arms (1), pedestals (2), and push tubes. Note the original location for re-assembly.
52. Remove the fuel connector tube nut and fuel connector tube. Remove cylinder #5 and #6 fuel injector.
53. Remove rocker housing.
54. Remove two cylinder head bolts (1) according to the diagram and install Tool #9009 (2). Torque bolts to 105 Nm (77 ft. lbs.).
55. Loosen but do not remove engine mount through bolts and nuts.
56. Disconnect hood support struts and position hood out of the way.
57. Attach a chain with two hooks to the engine lift brackets.
58. While keeping engine level, lift straight up out of the mounts.
59. Rotate nose of engine upward and pull out of chassis.
REMOVAL - CRANKCASE BREATHER- EARLY BUILD
1. Remove the oil fill cap.
2. Remove the breather cover bolts (1).
3. Remove breather cover (2).
4. Disconnect breather tube and lube oil drain tube from breather.
5. Remove breather mounting bolts (9).
6. Remove breather from cylinder head cover.
INSTALLATION - ENGINE
1. Remove cylinder head bolts (1,3) according to the diagram. Install special Tool 9009 (2). Torque bolts to 105 Nm (77 ft. lbs.).
2. Lower engine into the engine compartment and install the engine mount through bolts and nuts.
3. Tighten the mount through bolts and nuts to 88 Nm (65 ft. lbs.) torque.
4. Remove the engine lifting device (Tool 9009).
5. Check cylinder head capscrew length and install into cylinder head.
6. Torque in 4 steps to:
^ Step 1-Tighten to 70 Nm (52 ft. lbs.) torque.
^ Step 2-Back off 360°.
^ Step 3-Tighten to 105 Nm (77 ft. lbs.) torque.
^ Step 4-Rotate 90°.
7. Install rocker housing. Torque to 24 Nm (18 ft. lbs.).
8. Replace injector O-ring and sealing washer on injectors #5 and #6. Install injectors and torque using the following steps:
^ Step 1-Install injector hold-down capscrews and torque to 5 Nm (44 inch lbs.) torque.
^ Step 2-Loosen injector hold-down capscrews.
^ Step 3-Install HPC connector tube and nut. Torque nut to 15 Nm (11 ft. lbs.) torque.
^ Step 4-Torque injector hold-down capscrews to 10 Nm (89 inch lbs.) torque.
^ Step 5-Torque HPC connector tube nut to 50 Nm (37 ft. lbs.) torque.
9. Install rear engine lift bracket. Torque to 77 Nm (57 ft. lbs.).
10. Install #5 and #6 high pressure fuel lines. Follow correct torque sequence per section 14. Torque fuel line fittings to 30 Nm (22 ft. lbs.). Torque brace capscrew and nut to 24 Nm (18 ft. lbs.).
11. Install push tubes, rocker arms (1), and pedestals (2) for cylinders #4, #5, and #6. Torque the mounting bolts to 36 Nm (27 ft. lbs.).
12. Reset valve lash on cylinders #4, #5, and #6. Torque adjusting nuts to 24 Nm (18 ft. lbs.).
NOTE: For early builds, Verify proper installation of cylinder head cover ground spring (3) into cylinder head cover (2).
13. Install cylinder head cover (2). Torque to 24 Nm (18 ft. lbs.).
14. FOR EARLY BUILDS Connect breather tube and lube oil drain tube to breather housing cover. Install breather cover. Torque capscrews to 24 Nm (18 ft. lbs.).
15. FOR LATE BUILDS Install cylinder head cover carrier gasket (2).
16. FOR LATE BUILDS Connect injector harness nuts to injectors (1). Torque to 1.25 Nm (11 inch lbs.).
17. FOR LATE BUILDS Connect injector wiring harness connectors to injector connections on cylinder head cover carrier gasket (3).
18. FOR LATE BUILDS Install cylinder head cover (1).
19. FOR LATE BUILDS Connect breather tube (3) and lube oil drain tube (4) to cylinder head cover (2).
20. Connect fuel supply and return hoses.
21. Connect ECM ground to hydroform screw. Connect ECM power connector.
22. Install the power steering pump.
23. Install the damper and speed indicator ring. Torque to 40 Nm (30 ft. lbs.) plus 60 degrees.
24. Install lower fan shroud bracket (3). Torque to 24 Nm (18 ft. lbs.).
25. Install upper fan shroud brackets, but do not tighten fasteners at this time.
26. Connect the engine block heater connection.
27. Connect the A/C compressor and pressure sensor connectors.
28. Install the charge air cooler (2). Install and tighten the charge air cooler mounting bolts(1) to 2 Nm (17 inch lbs.).
29. Connect the charge air cooler tubes(4). Torque all clamps to 8 Nm (72 inch lbs.).
30. Install the a/c condenser (1).
31. Connect the a/c refrigerant lines to the a/c condenser.
32. Install the radiator upper support panel.
33. Install radiator.
34. Connect the transmission quick-connect oil cooler lines.
35. Raise vehicle.
36. Connect a/c compressor suction/discharge hose (if equipped).
37. Install the radiator lower hose and clamps.
38. Install the battery negative cables to the engine block on the driver and passenger side.
39. Install the transmission adapter with a new camshaft rectangular ring seal. Torque to 77 Nm (57 ft. lbs.).
40. FOR EARLY BUILDS Install the flywheel/flexplate. Torque to 137 Nm (101 ft. lbs.).
41. FOR LATE BUILDS Install the flywheel and adapter or flexplate. Torque to 137 Nm (101 ft. lbs.).
42. Install the starter motor (2). Torque to 43 Nm (32 ft. lbs.).
43. Connect engine to vehicle harness connectors.
44. Install transmission and transfer case (if equipped).
45. Connect the exhaust pipe to the turbocharger elbow.
46. Connect the transmission auxiliary oil cooler lines (if equipped).
47. Lower the vehicle.
48. Connect the heater core supply and return hoses.
49. Install the cooling fan (3) and fan drive (2).
50. Install the fan shroud mounting bracket (3) and shroud..
51. Install the windshield washer bottle.
52. Install the upper radiator hose and clamps.
53. Raise vehicle.
54. Change oil filter and install new engine oil.
55. Fill the cooling system with coolant.
56. Connect grid heater harness at grid heater relays.
57. Connect electrical connections to rear of alternator.
58. Start the engine and inspect for engine oil, coolant, and fuel leaks.
INSTALLATION - CRANKCASE BREATHER- EARLY BUILD
1. Install a new O-ring onto the breather element.
2. Lubricate O-ring and install into cylinder head cover. Torque capscrews to 10 Nm (89 inch lbs.).
3. Connect breather tube and lube oil drain tube.
4. Install breather cover. Torque to 24 Nm (18 ft. lbs.).
5. Install oil fill cap.