Removal
Engine
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. NOTE: Index-mark the hood hinge location to aid in hood installation.
NOTE: RH shown, LH similar.
Remove the 4 bolts (2 shown) and the hood.
3. Release the fuel system pressure.
4. Disconnect the battery ground cable.
5. If equipped, disconnect the block heater electrical connector at the thermostat housing.
- Detach the block heater wiring harness retainer from the LH valve cover stud bolt and position aside.
6. Remove the cooling module.
7. Remove the LH and RH turbocharger intake tubes.
8. Remove the 2 Charge Air Cooler (CAC) inlet tubes and the CAC (Charge Air Cooler) outlet tube.
9. Disconnect the Battery Junction Box (BJB) wiring harness and the A/C pressure transducer electrical connectors.
10. Remove the nut and disconnect the A/C tube.
- Discard the O-ring seal and gasket seal.
11. Remove the nut and the transmission cooler line bracket from the engine front cover stud bolt.
12. Detach the generator wiring harness from the engine front cover.
13. Disconnect the A/C compressor electrical connector.
- Detach the A/C compressor wiring harness from the A/C compressor.
14. Remove the generator.
15. Remove the A/C compressor belt.
16. Disconnect the PCM electrical connector and the engine wire harness electrical connector.
- Detach the wiring harness retainers from the fender splash shield.
17. Remove the fuel injection pump.
18. Remove the intake manifold. For additional information, refer to Intake Manifold Service and Repair.
19. Disconnect the 2 heater hose couplings at the RH rear of the engine.
20. Disconnect the 2 coolant hoses from the degas bottle.
21. Detach the wiring harness retainers from the rear of the RH valve cover stud bolt and the rear of the RH cylinder head.
22. Remove the bolt and the ground strap from the cowl.
23. Remove the cowl panel grille.
24. Remove the 6 screws and release the 2 cowl panel clips and remove the cowl panel.
25. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector from the engine wiring harness at the rear of the LH cylinder head.
- Disconnect the HO2S (Heated Oxygen Sensor) electrical connector from the wiring harness retainer.
26. Release the 4 fasteners and the splash shield.
27. NOTE: Only one wire harness retainer and one electrical connector shown, others similar.
Disconnect the 2 HO2S (Heated Oxygen Sensor) electrical connectors.
- Disconnect the 2 HO2S (Heated Oxygen Sensor) electrical connector retainers.
- If equipped, disconnect the 5 transmission wire harness retainers from the transfer case wire harness.
28. Disconnect the HO2S (Heated Oxygen Sensor) electrical connector at the LH rear of the transmission.
- Disconnect the electrical connector retainer from the bracket at the rear of the transmission.
29. NOTICE: Do not pull on the wire harness to disconnect the connector or damage to the connector will occur.
Disconnect the transmission vehicle harness connector by twisting the outer shell and pulling back on the connector.
30. Remove the 4 bolts and the skid plate.
31. If equipped, remove the front driveshaft.
32. Remove the starter motor.
33. Detach the starter motor wiring harness retainer from the oil pan.
34. Remove the 2 pin-type retainers and the access cover.
35. NOTE: Index-mark the end of one torque converter stud and the flexplate for installation.
Remove the 4 torque converter nuts.
36. Remove the 2 exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolts and separate.
- Discard the bolts.
37. NOTE: LH shown, RH similar.
Remove and discard the 2 LH and RH catalytic converter-to-exhaust manifold nuts.
38. Remove the drain plug and drain the engine oil.
- Install the drain plug and tighten to 27 Nm (20 lb-ft).
39. Remove and discard the engine oil filter.
40. NOTE: The 2 engine mount studs may come off with the nuts.
Remove the 2 RH engine support insulator nuts and studs.
41. Remove the engine-to-bellhousing bolt.
42. Remove the oil pan-to-bellhousing bolt.
43. Remove the 2 LH bellhousing-to-engine bolts.
44. Remove the 4 upper bellhousing-to-engine bolts.
45. Remove the LH engine mount through bolt.
46. NOTICE: Do not support the transmission by the fluid pan, failure to follow this instruction may result in serious damage to the transmission.
Support the bellhousing of the transmission with a suitable floor jack and a block of wood.
47. Remove the 2 LH bellhousing-to-oil pan bolts.
48. Remove the 2 nuts and the CAC (Charge Air Cooler) tube bracket.
- Disconnect the coolant hose from the valve cover stud.
49. Install the Right Front Lift Eye.
50. Using part of the Engine Lifting Bracket and a chain, assemble the Engine Spreader Bar as shown.
51. NOTE: After removing the bolts leave the LH engine support insulator in place.
Remove the 3 bolts for the LH engine support insulator.
52. NOTE: The use of a ratchet strap may be needed to level the engine.
Using the Floor Crane and Engine Spreader Bar assembly, lift the engine.
53. Remove the LH engine support insulator.
54. NOTE: The transmission wiring harness is part of the engine wiring harness.
Detach the generator wiring harness retainer from the lower LH side of the engine block.
- Position the transmission wiring harness on top of the engine for removal.
55. Using the Floor Crane and Engine Spreader Bar assembly, remove the engine.
56. Install the Torque Converter Retainer.
