Removal
Engine
Special Tool(s)
Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the LH and RH battery ground cables.
Vehicles with manual transmission
3. NOTE: On vehicles equipped with manual transmissions, the transmission must be removed before the engine can be removed.
Remove the transmission.
4. Remove the clutch disc and pressure plate.
All vehicles
5. Remove the cooling fan stator.
6. Remove the air cleaner assembly.
7. Remove the charge air cooler.
Vehicles with A/C
8. Remove the A/C condenser assembly.
All vehicles
9. Remove the radiator grille opening panel reinforcement.
10. Remove the front bumper.
11. Loosen the clamps and disconnect the power steering cooler hoses.
- Plug or cap the openings as needed.
12. Disconnect the power steering tubes from the retaining clip and position aside.
13. Remove the bolts and power steering cooler.
14. Disconnect the transmission cooler hoses.
- Plug or cap the openings as needed.
15. Remove the bolts and the transmission oil cooler.
16. Remove the retaining nut and position the body feed cable aside.
17. Remove the bolts and upper radiator support.
18. Remove the intake manifold.
19. Remove the bolts and the battery tray.
20. Disconnect the LH glow plug electrical connector.
21. Disconnect the powertrain control module (PCM) electrical connectors.
22. Disconnect the 12-pin and 8-pin electrical connectors.
23. Disconnect the camshaft position (CMP) sensor electrical connector.
24. Disconnect the heater hose at the front cover.
25. Remove the lower radiator hose clamp and the hose.
26. Remove the clips and disconnect the fuel lines.
27. NOTE: Only one stand-off shown.
Remove the stator stand-offs.
28. Remove the power steering pump upper mounting bolts.
29. Remove the bolt and position the power steering pump aside.
30. Remove the nut and the battery cable bracket.
31. Remove the ground stud and the ground cable.
32. NOTE: Only one retainer shown.
Disconnect the wire retainers from the valve cover studs.
33. Disconnect the injection control pressure (ICP) sensor electrical connector and wiring retainer. Disconnect the glow plug module electrical connectors.
34. Disconnect the RH glow plug electrical connector.
Vehicles with A/C
35. Disconnect the A/C high-pressure switch and the A/C clutch electrical connectors.
36. Remove the retaining nut and disconnect the A/C hose.
- Remove and discard the O-ring seal.
- Plug or cap the openings as needed.
37. Remove the A/C compressor.
All vehicles
38. Disconnect the crankshaft position (CKP) sensor electrical connector and position the wiring aside.
Vehicles with automatic transmission
39. Remove the automatic transmission fluid indicator and tube.
All vehicles
40. Remove the ground strap at the back of the right head.
41. Remove the solenoid cap and disconnect the starter wiring.
42. If equipped, disconnect the block heater electrical connector.
43. Position the block heater and starter wiring harness out of the way.
Vehicles with automatic transmission
44. Remove the torque converter cover.
45. Remove and discard the torque converter nuts.
All vehicles
46. NOTE: LH shown; RH similar.
Remove the bolts for the turbocharger adapter pipe.
47. NOTE: RH shown; LH similar.
Remove the motor mount nuts.
48. Drain the engine oil.
49. Loosen the nuts at the turbocharger adapter pipe flange.
Vehicles with automatic transmission
50. Remove the nine bellhousing bolts.
All vehicles
51. Remove the turbocharger adapter pipe.
Late build vehicle
52. Disconnect the exhaust pressure sensor electrical connector.
53. To remove the exhaust pressure sensor tube assembly, remove the exhaust pressure sensor tube retaining nut and disconnect the exhaust pressure sensor tube fitting at the exhaust manifold.
All vehicles
54. Remove the nuts and the fuel injector control module bracket.
55. Remove the left rear valve cover stud.
56. Remove the transmission cooler line bracket.
57. Secure the turbocharger outlet pipe.
58. Remove the manufacturer's lifting eye.
59. Install the engine lifting eye on the RH cylinder head.
60. Install the front lifting brackets.
Vehicles with automatic transmission
61. Position a suitable jack under the transmission.
All vehicles
62. Install the Heavy Duty Floor Crane and Diesel Engine Lifting Bracket on the engine.
63. Raise the engine high enough to clear the No. 1 crossmember and pull the engine forward and clear of the vehicle.
64. Remove the engine lifting equipment from the engine.