Removal
EngineSpecial Tool(s):
Material:
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
2. Disconnect the battery ground cable. For additional information, refer to Battery.
3. Remove the A/C condenser assembly. For additional information, refer to Heating and Air Conditioning.
4. Remove the front bumper.
5. Remove the radiator grille support.
6. Remove the intake manifold.
7. Remove the bolts, disconnect and remove the air bag sensor. Position the headlamp wiring harness aside.
8. NOTE: Mark the latch before removal.
Remove the 2 bolts and hood latch.
9. NOTE: RH shown, LH similar.
Remove the 8 bolts and the upper radiator support.
10. NOTE: LH shown, RH similar.
Remove the 12 bolts and lower radiator support.
11. Remove the RH fan stator stand-off. Remove the bolt and position the cable aside.
12. Disconnect the A/C electrical connector.
13. Disconnect the A/C pressure switch and remove the A/C manifold from the tee block.
^ Remove and discard the O-ring seals.
^ Cap or plug the A/C openings as needed.
14. Remove the bolts and A/C compressor.
15. Disconnect the heater hose and position the heater hose and tube aside.
16. Remove the bolt and idler pulley.
17. Disconnect the engine coolant fill hose from the retaining clip and loosen the clamp and remove the engine coolant fill hose.
18. Disconnect the vacuum pump hose and remove the engine coolant fill hose clip.
19. NOTE: The bolt behind the pulley is accessed thorough the pulley with an extension and a short socket.
Remove the bolts and the vacuum pump.
20. Remove the power steering upper mounting bolts.
21. Remove the LH fan stator stand-off.
22. NOTE: The front bolt will remain in the power steering pump.
Remove the 2 bolts and position the power steering pump aside.
23. Remove the lower radiator hose.
24. Disconnect the fuel tube spring lock couplings. For additional information, refer to Fuel Delivery and Air Induction.
25. Disconnect the crankshaft position (CKP) sensor electrical connector and retaining clips.
26. Disconnect the injection control pressure (ICP) sensor electrical connector. Disconnect the glow plug electrical connector and wire retainers.
27. Disconnect the camshaft position (CMP) sensor electrical connector and retaining clips.
28. Disconnect the electrical connector and wire retainers at the transmission.
29. Disconnect the glow plug module electrical connectors.
30. Disconnect the exhaust pressure sensor electrical connector and pushpin retainer.
31. Disconnect the LH glow plug electrical connector.
32. Disconnect the 2 engine-to-vehicle electrical connectors.
33. Disconnect the 2 powertrain control module (PCM) electrical connectors and position the engine wiring harness aside.
34. Remove the 3 bolts and the oil filter assembly.
35. Remove the nut and remove the transmission cooling tubes support bracket off the stud.
36. Remove the retaining clips from the transmission tubes.
37. Using the special tool, disconnect transmission cooler tubes.
38. Remove the torque converter cover.
39. Remove and discard the torque converter nuts.
40. Disconnect the block heater electrical connector.
41. Remove the nut. Disconnect the battery cable bracket at the starter and position aside.
42. Remove the starter solenoid protective cap.
43. Disconnect the starter motor electrical connections.
44. Remove the bolts and the starter motor.
45. NOTE: Right side shown, left side similar.
Remove the cylinder block drain plugs and drain the coolant from the block.
46. NOTE: Apply clean engine oil to the O-ring seal prior to installation.
Install the cylinder block drain plugs.
^ Tighten to 20 Nm (15 ft. lbs.).
47. NOTE: Left side shown, right side similar.
Remove the 4 engine mount nuts.
48. Remove the lower engine-to-transmission bolts.
49. Remove the mounting bolts from the lifting bracket and remove the tubes.
50. Disconnect the glow plug wire retainer and remove the nut and the oil indicator and tube.
^ Discard the O-ring seal.
51. Disconnect the exhaust pressure tube at the exhaust manifold.
52. Remove the nuts and glow plug module.
53. Remove the nuts and the glow plug module mounting bracket.
54. NOTE: Mark the location of the studs prior to removal.
Remove the bolts and the LH valve cover.
^ Remove the valve cover gasket.
^ Cover the cylinder head after the valve cover is removed.
55. Remove the ICP sensor.
^ Plug or cap the opening as needed.
56. NOTE: Do not tighten the bolts at this time.
Install the special tools.
57. Remove the turbocharger exhaust pipe.
58. Remove the bolt and the ground strap.
59. Remove the factory-installed engine lifting bracket.
60. Install the special tool.
61. Install the engine lifting attachment and lifting crane.
62. Remove the oil pan drain plug and drain the engine oil.
63. NOTE: It may be necessary to raise the engine for oil pan removal. Disconnect the linkage from the engine lifting attachment to raise the engine.
NOTE: The oil pan bolts must be reinstalled in their original positions. Mark the location of the longer bolts to aid in installation.
Remove the bolts and position back the oil pan until the oil pickup tube bolts are accessible.
64. Remove the 2 bolts and let the oil pickup tube go into the oil pan. Remove the oil pan.
65. Remove the press-in-place gasket and discard.
66. Remove and discard the oil pick-up tube O-ring seal.
67. Position a suitable transmission jack under the transmission.
68. Remove the upper engine-to-transmission bolts.
69. Raise the engine.
70. Remove the 4 bolts and LH engine mount.
71. Remove the 4 bolts and the RH engine mount.
72. NOTE: The engine must be moved to the driver side for removal.
Remove the engine from the vehicle.