Engine - Removal

REMOVAL - ENGINE




1. 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.




43. Remove the cylinder head cover (1).
44. Disconnect the wire harnesses from the injectors (3).
45. Remove the cylinder head cover carrier gasket (2).

NOTE: Extreme care should be used to keep dirt/debris from entering the fuel lines. Plastic caps should be used on the ends of the fuel lines.

46. Loosen #6 fuel line shield bolts and rotate shield out of the way.
47. Remove cylinder #5 and #6 high pressure fuel lines.
48. Remove the rear engine lift bracket.




49. Remove cylinder #4, #5, and #6 intake and exhaust rocker arms (1), pedestals (2), and push tubes. Note the original location for reassembly.
50. Remove the fuel connector tube nut and fuel connector tube. Remove cylinder # 5 and # 6 fuel injector.
51. Remove rocker housing.




52. Remove two cylinder head bolts (1) according to the diagram and install Tool # 9009 (2). Torque bolts to 105 Nm (77 ft. lbs.).
53. Loosen but do not remove engine mount through bolts and nuts.
54. Disconnect hood support struts and position hood out of the way.
55. Attach a chain with two hooks to the engine lift brackets.
56. While keeping engine level, lift straight up out of the mounts.
57. Rotate nose of engine upward and pull out of chassis.