Removal
Engine
Special Tool(s)
Removal
All vehicles
1. Disconnect both battery ground cables.
2. Loosen the clamps and remove the air cleaner outlet tube.
3. Remove the air intake tube and adapter.
1 Loosen the clamp.
2 Remove the bolts.
3 Lift the tube and adapter, disconnect the wastegate pressure hose, and remove the tube and adapter from the vehicle.
4. Remove the degas bottle.
Vehicles equipped with A/C
5. Recover the refrigerant.
All vehicles
6. Remove the radiator grille, and the radiator grille opening panel.
7. Remove the bolts and position the hood latch aside.
8. Remove the three right side air deflector pushpins.
9. NOTE: Left side shown, right side similar.
Remove the air charge cooler retainers.
10. Remove the radiator brackets and position the battery cable aside.
1 Remove the bolts and the brackets.
2 Detach the retainers and position the battery cables aside.
11. NOTE: Right side shown, left side similar.
Remove the eight bolts and the radiator upper support.
12. Remove the radiator sight shield.
Vehicles equipped with A/C
13. Disconnect the A/C condenser core inlet and outlet tubes.
14. Remove the A/C condenser.
All vehicles
15. NOTE: Both the inlet and outlet ducts are removed the same way. Only the outlet duct is shown.
Remove the inlet and outlet ducts from the charge air cooler.
1 Loosen the clamp.
2 Detach the ducts from the charge air cooler.
16. Remove the charge air cooler.
17. Disconnect the upper radiator hose from the radiator.
18. Remove the bolts and position the fan shroud on the fan.
19. Raise the vehicle.
20. Disconnect the degas supply and lower radiator hoses from the radiator.
21. Lower the vehicle.
22. Remove the radiator.
23. Remove the fan shroud.
24. CAUTION: The large clutch assembly nut has a right-hand thread and must be rotated counterclockwise to remove it.
Using the special tools, remove the fan and the fan clutch from the water pump pulley.
25. Rotate the belt tensioner counterclockwise and remove the drive belt.
26. Disconnect the Manifold Absolute Pressure (MAP) sensor hose from the turbocharger compressor manifold.
27. 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.
Vehicles equipped with A/C
28. Disconnect the A/C compressor electrical connector, if so equipped.
29. Disconnect the A/C manifold from the A/C compressor, if so equipped.
All vehicles
30. Disconnect the power steering hoses.
31. Disconnect the generator electrical connectors.
32. Remove the generator mounting bracket.
1 Remove the bolts.
2 Remove the mounting bracket.
33. Remove the bolt from the left front of the engine block.
34. Disconnect the engine control sensor wiring electrical connector.
35. Disconnect the lower generator electrical connectors.
All vehicles
36. Disconnect the fusible link.
1 Remove the nuts.
2 Disconnect the cable and the fusible link.
37. Disconnect the ground strap.
38. Disconnect the heater return hose.
39. Disconnect the heater supply hose.
40. Remove the turbocharger.
41. Using the fuel line tool, disconnect the fuel lines.
42. NOTE: The fuel line retaining bolt must be removed before installing the engine lift adapters.
Remove the fuel line retaining bolt.
43. Remove the idler pulley.
1 Remove the bolt.
2 Remove the idler pulley.
44. Remove the nuts and position the glow plug and intake air heater relays aside.
45. Remove the bolts and the water outlet tube.
46. Install two engine lift adapters.
47. Install the special tool on the right side cylinder head.
Vehicles equipped with an automatic transmission
48. Raise the vehicle.
49. Disconnect the starter motor electrical connectors.
1 Remove the nuts.
2 Remove the battery cable.
3 Remove the starter solenoid wire.
50. Remove the three bolts and the starter.
51. Remove the torque converter housing cover.
52. NOTE: Mark one stud and the flexplate for assembly reference.
Remove the torque converter-to-flexplate nuts.
Vehicles equipped with manual transmissions
53. Remove the transmission.
All vehicles
54. Remove the oil filter.
55. Disconnect the block heater electrical connector.
56. Remove the engine mount nuts.
Vehicles equipped with an automatic transmission
57. Remove the transmission-to-engine bolts.
58. Lower the vehicle.
59. Use a wood block and a suitable jack to support the transmission.
60. Remove the transmission oil level indicator tube.
All vehicles
61. Install the Heavy Duty Floor Crane and the Diesel Engine Lifting Bracket on the engine.
62. Raise the engine high enough to clear the No. 1 crossmember and pull the engine forward out of the vehicle.
63. Remove the engine lifting equipment from the engine.