Engine - Removal - Body Off

Engine - Body Off





Removal

All vehicles

NOTE: It is recommended that this component be serviced with the vehicle body removed. If the body cannot be removed, refer to Engine - Body On Engine - Removal - Body On.

1. With the vehicle in NEUTRAL, position the vehicle on a hoist. For additional information, refer to Vehicle Jacking and Lifting.

2. Disconnect the battery ground cable(s). For additional information, refer to Battery.

3. Release the fuel pressure. For additional information, refer to Fuel Delivery and Air Induction.

4. Remove and discard the 4 RH engine mount retaining nuts.





5. Remove and discard the 3 LH engine mount retaining nuts.





6. Loosen the 2 transmission mount nuts.





7. Remove the oil pan drain plug and drain the oil.





8. Install the drain plug.
- Tighten to 44 Nm (32 lb-ft).





9. NOTE: Automatic transmission shown, manual transmission similar.

Remove the 5 lower engine-to-transmission bolts.





10. Remove the body.

11. Remove the turbocharger exhaust downpipe clamp.
- Discard the turbocharger clamp and gasket.





12. Remove the 2 bolts and the turbocharger exhaust downpipe.





Vehicles with automatic transmission

13. Remove the retaining nut and the transmission fluid indicator and tube.
- Plug or cap the opening.





All vehicles

14. If equipped, disconnect the block heater cord.





15. Remove the retaining nut and disconnect the battery cable bracket.





16. Remove the cover for the starter wiring.





17. Remove the 2 retaining nuts for the starter wiring and position the starter wiring aside.





18. NOTE: RH side shown, LH side similar.

Mark the location of the bumper. Remove the 6 bolts and the bumper.





19. Remove the bolt and position the battery ground cable aside.





20. If equipped, remove the nut and position the steering damper aside.





21. Remove the nut and disconnect the transmission cooling tubes.





22. Disconnect the fuel hoses.





Vehicle with automatic transmission

23. Remove the flexplate access cover.





24. Remove and discard the 8 torque converter nuts.





All vehicles

25. Disconnect the retainers for the power steering hose.





26. Disconnect the clip and separate the 2 power steering hoses. Secure the hose from the power steering pump to the engine.





27. Mark the location of the tires on the floor prior to rolling out the chassis. Roll the chassis out from under the body.

28. Remove the clamp at the crankcase vent oil separator. Loosen the clamp and remove the Air Cleaner (ACL) outlet pipe.
- Discard the clamp on the crankcase vent oil separator.





Vehicles with dual generators

29. Remove the secondary generator. For additional information, refer to Charging System.

All vehicles

30. Install an Engine Lifting Bracket on the Front End Accessory Drive (FEAD) bracket.





31. Install an Engine Lifting Bracket on the back of the right cylinder head.





32. Position a suitable transmission jack under the transmission.

33. Position a Heavy Duty Floor Crane with a commercially available load leveler and connect the load leveler to the Engine Lifting Brackets. Install a ratcheting strap from the hook to the lifting eye to aid in holding the engine level.





34. Remove and discard the LH engine mount bolt.





35. NOTE: Automatic transmission shown, manual transmission similar.

Remove the 4 upper engine-to-transmission bolts.





36. Raise the Heavy Duty Floor Crane and the transmission jack together until the engine clears the insulator. Remove the engine from the vehicle.

Vehicles with manual transmission

37. Remove the clutch disc and pressure plate. For additional information, refer to Clutch, M/T.