Removal

Special Tools:

1. Disconnect both battery ground cables.

2. NOTE: On vehicles equipped with manual transmissions, the transmission must be removed before the engine can be removed.

Remove the transmission.
3. Remove the air inlet duct.
4. Remove the turbocharger.
5. Remove the radiator.
6. Remove the charge air cooler.
7. Remove the A/C condenser assembly, if so equipped.
8. Remove the parking lamp and the headlamp assemblies.
9. Remove the radiator grille, the radiator grille opening panel, and the upper and lower radiator core supports.
10. Remove the front bumper.
11. Remove the accessory drive belt.

12. Disconnect the generator electrical connectors.

13. Disconnect the Manifold Absolute Pressure (MAP) sensor hose from the turbocharger compressor manifold.

14. Remove the compressor manifold.
1. Loosen the clamps.
2. Remove the compressor manifold.

15. NOTE: Steps 15 and 16 apply only to vehicles equipped with a dual generator system.

Disconnect the lower generator electrical connectors.

16. Remove the engine ground cable from the right side of the engine block.
1. Remove the nut.
2. Remove the starter wire retaining bracket.
3. Remove the engine ground cable.

17. Disconnect the electrical connector from the A/C compressor, if so equipped.

18. Disconnect the air conditioning manifold lines from the A/C compressor, if so equipped.

19. Disconnect the power steering lines.

20. NOTE: Step 20 applies only to vehicles equipped with a single generator.

Remove the ground cable from the right side of the engine block.
1. Remove the stud bolt.
2. Remove the ground cable.

21. Disconnect the engine control sensor wiring.

22. Disconnect the ground strap.

23. Disconnect the heater return hose.

24. Disconnect the heater supply hose.

25. Using the Fuel Line Tool, disconnect the fuel lines.

26. NOTE: Step 26 applies only to vehicles equipped with automatic transmissions.

Remove the transmission sensor harness retaining bolt and the harness.

27. NOTE: The fuel line retaining bolt must be removed before the engine lift adapters can be installed.

Remove the fuel line retaining bolt.

28. Install the two engine lift adapters.
29. Install the engine Lifting Eye on the right side cylinder head, if required.
30. Raise and support the vehicle.
31. Remove the starter motor.

32. Remove the engine mount nuts.

33. NOTE: Steps 33 and 34 apply only to vehicles equipped with automatic transmissions.

Remove the flywheel housing cover.

34. Remove the torque converter-to-flywheel retaining nuts.
35. Remove the oil filter.

36. Disconnect the block heater.

37. NOTE: Steps 37 through 40 apply only to vehicles equipped with automatic transmissions.

Remove the transmission-to-engine bolts.
38. Lower the vehicle.
39. Position a suitable jack under the transmission.
40. Remove the transmission fill tube.
41. Install the Heavy Duty Floor Crane and Diesel Engine Lifting Bracket on the engine.

42. Raise the engine high enough to clear the No.1 crossmember and pull the engine forward.
43. Remove the engine lifting equipment from the engine.
44. Remove the flywheel.
45. Mount the engine on a work stand, using the Engine Mounting Brackets.