Engine - Removal

ENGINE ASSEMBLY





1. Open the hood.
2. Remove engine hood.Hood - Removal





3. Disconnect the remote battery ground.





4. Remove air intake hose downstream of air filter on air filter housing.
5. Disconnect electrical connectors.
6. Disconnect the jump-starting point on air filter housing and place to one side.
7. Pull out air intake hose upstream of air filter on front module.
8. Lift the air filter housing at front from front module and pull out of the rear guides.
9. Remove the air filter housing bracket from the bulkhead.
10. Disconnect electrical connector at intake manifold pressure sensor.
11. Unscrew bolts at intake manifold pressure sensor.
12. Remove intake manifold pressure sensor.
13. Remove hot film mass air flow sensor.





14. Remove front module.
15. Remove holder for air filter housing to front plate.
16. Remove trim panel on right cylinder head cover.
17. Remove trim panel on left cylinder head cover.
18. Place gearshift into neutral.
19. Disconnect and remove the auxiliary battery.Battery Cables - Removal
20. Remove battery tray for additional battery.Auxiliary Battery Tray - Removal
21. Raise and support the vehicle.





22. Drain the coolant.Service and Repair










23. Disconnect the speed sensors on transmission.
24. Detach shift cables on manual transmission.
25. Disconnect the oxygen sensors.










26. Remove the coolant lines from the heater core.
27. Remove the upper radiator hose at the radiator and position aside.
28. Remove the lower radiator hose at the radiator and position aside.





29. Remove the vacuum line at the vacuum pump.
30. Disconnect the engine ground.
31. Disconnect the ECM.
32. Remove the power steering lines at the power steering pump and plug the lines.










33. Remove clamp and disconnect exhaust system between catalytic converter and diesel particulate filter.










34. Remove propeller shaft center support bearing on frame floor assembly.
35. Detach power take-off connections.
36. Remove bolts, remove propeller shaft on manual transmission and hang to the side outside the working area.










CAUTION: The manual transmission must not lie on the crossmember after loosening the rear engine mount.

37. Insert suitable wooden block between manual transmission and crossmember.
38. Attach engine removal chains to the lift points.





39. Remove bolts on right engine mount at the front.





40. Remove bolts on left engine mount at the front.










41. Use appropriate engine hoist to lift the engine and manual transmission from the vehicle.