Part 1

Engine Replacement


Special Tools
* J 36857 Engine Lift Bracket
* J 43181 Heater Line Quick Connect Release Tool



Removal Procedure


Important: In order to remove the engine, the vehicle needs to be on a hoist. The front wheels and tires will also require removal. The vehicle will have to be supported by the frame when the tires are removed.


1. Remove the engine cover. Refer to Engine Cover Replacement .
2. Remove the cooling layer. Refer to Cooling Layer Removal (Service and Repair) .
3. Remove the cooling fan. Refer to Fan Replacement (Service and Repair) .
4. Remove the drive belt. Refer to Drive Belt Replacement (Service and Repair) .
5. Disconnect the generator electrical connector.
6. Remove the positive battery cable from the generator, perform the following:

* Slide the boot down to access the terminal stud.
* Remove the positive cable nut.
* Remove the positive cable.





7. Remove the generator bolts (1).
8. Remove the generator (2).
9. Disconnect the RH engine wiring harness connector.




10. Remove the 2 RH engine wiring harness bracket bolts and position aside.




11. Remove the 2 wiring harness routing bolts.




12. Remove the oil indicator tube bracket bolt.




13. Remove the drive belt tensioner bolt and tensioner.




14. Remove the bolts and the generator mounting bracket.
15. If equipped, remove the auxiliary generator. Refer to Auxiliary Generator Replacement .




16. Remove the auxiliary generator bracket bolt and bracket, if equipped.
17. If equipped with a dual generator system, remove the bolt from the left side idler pulley and remove the idler pulley.
18. Disconnect the air conditioning (A/C) compressor clutch electrical connector.
19. Disconnect the A/C cut out switch electrical connector.




20. Remove the A/C compressor bolts.
21. Remove the A/C compressor.




22. Remove the power steering pump and bracket bolts (1).
23. Remove the power steering pump bracket (2) from the pump.
24. Position the power steering pump aside and secure.




25. Remove the rear power steering pump bracket bolts (1) from the bracket.




26. Remove the fuel line bolt and position the fuel line aside.




27. Compress the clamp and disconnect the turbocharger inlet cooling hose/pipe.




28. Remove the oil fill tube bolts and the oil fill tube.
29. Remove the exhaust gas recirculation (EGR) valve coolant pipe to thermostat housing bolt.




30. Disconnect the coolant temperature sensor electrical connector.
31. Remove the fuel pipe bracket bolt.




32. Remove the 8 thermostat housing crossover bolts and the thermostat housing crossover.
33. Remove the thermostat pipe. Refer to Thermostat Bypass Pipes Replacement (Service and Repair) .




34. Disconnect the intake air heater (IAH) electrical connector.




35. Disconnect the engine harness electrical connector from the manifold absolute pressure (MAP) sensor.




36. Disconnect the positive cable from the IAH by performing the following:

* Reposition the positive battery cable boot.
* Remove the positive battery cable nut at the IAH.
* Remove the positive battery cable from the IAH stud.





37. Remove the engine wiring harness clip bolt (1) at the rear of the intake manifold tube.
38. Remove the 2 rear intake manifold tube bolts (3).
39. Remove the rear intake manifold tube nut (2).
40. Remove the engine wiring harness clip from the intake manifold tube.
41. Remove the engine wiring harness clip bolt (3).
42. Remove the EGR cooler water pipe bracket bolt (5).
43. Remove the intake manifold tube bolts (2, 4) and nut (1).




44. Remove the intake manifold tube with the stud.
45. Remove and discard the 2 metal EGR gaskets from the EGR valve.
46. Remove and discard the O-ring seal from the center intake manifold.
47. Remove the air intake pipe. Refer to Air Intake Pipe Replacement .
48. Remove the right exhaust pipe. Refer to Exhaust Pipe Replacement - Right Side (6.6L (LMM)) () .
49. Remove the left exhaust pipe. Refer to Exhaust Pipe Replacement - Left Side (6.6L (LMM)) () .
50. Remove the EGR coolant hose. Refer to Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (LLY, LBZ) () .




51. Compress the clamp and disconnect the EGR heater inlet hose/pipe from the EGR cooler tube.




52. Remove the EGR cooler tube bracket bolt.
53. Remove the crankcase ventilation hose/pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (LMM) () .




54. Disconnect the EGR solenoid electrical connector.




55. Remove the EGR nut (1) and bolt (2).
56. Remove the EGR valve and EGR cooler tube as an assembly.




57. If necessary, remove the EGR bracket bolt, nut, and EGR bracket.




58. Remove the 2 bolts and the EGR cooler tube bracket.




59. Disconnect the engine wiring harness electrical connector from the turbocharger vane position sensor.
60. Disconnect the engine wiring harness electrical connector from the turbocharger vane control solenoid valve.




61. Remove the turbocharger upper heat shield bolts.
62. Remove the turbocharger upper heat shield.





Important: Use care not to damage this hose during the procedure.


63. Reposition the turbocharger coolant outlet pipe clamp (1) and remove the hose from the turbocharger pipe.
64. Using the J 36857 and J 43181 , disconnect the fuel feed and return pipes.
65. Disconnect the positive battery cable from the glow plug control module.
66. Remove the glow plug control module bolts.
67. Remove the glow plug control module.




68. Remove the glow plug control module bracket bolts (2).
69. Remove the fuel line bracket bolt (1).
70. Remove the glow plug control module.




71. Remove the fuel line bracket bolt.

Important: Use care not to damage this hose during the procedure.


72. Remove the turbocharger coolant inlet pipe bolt and remove the hose from the turbocharger.




73. Remove the turbocharger oil feed pipe banjo bolt and washer. Discard the banjo bolt and washer.
74. Reposition and secure the turbocharger oil fed pipe out of the way.




75. Remove the turbocharger oil return pipe nuts (1) at the top of the flywheel housing.




76. Remove the turbocharger bolts.
77. Remove the turbocharger (with the oil return pipe).
78. Remove and discard the turbocharger oil return pipe gasket at the flywheel housing.
Remove the turbocharger lower heat shield.




79. Remove the turbocharger oil feed pipe, washer, and pipe.




80. Disconnect the LH main engine wiring harness connector and remove the bracket bolts (1).




81. Remove the LH glow plug nuts (2) and the routing bolts (1).




82. Disconnect the fuel injector electrical connectors.




83. Disconnect the intake air temperature sensor 2 and fuel rail temperature sensor electrical connector.




84. Disconnect the ECT wiring harness electrical connector (1) and the oil pressure sensor electrical wiring harness electrical connector (2).
85. Position the engine wiring harness over the RH side of engine.




86. Remove the nut, the 2 bolts and position the bracket aside.




87. Remove the fuel feed/return pipe bracket bolt.




88. Disconnect the fuel hoses from the fuel pipe.




89. Remove the fuel line bracket bolt.




90. Disconnect the fuel pump hose from the fuel pipe.




91. Remove the fuel pipe.




92. Remove the fuel pipe clamp bolt (2) and turbocharger coolant inlet pipe bracket bolt (3).




93. Remove the 4 center intake manifold bolts (1) and 4 nuts (2).
94. Remove the center intake manifold.




95. Remove the fuel pump to LH fuel rail pipe.




96. Compress the clamp and remove the fuel pressure relief hose.




97. Remove the fuel pipe bracket bolt (2), disconnect the hose (1) at the fuel pump and remove the fuel pipe/hose assembly.




98. Remove the LH to RH fuel rail pipe.




99. Remove the LH fuel injector feed pipes.




100. Remove the 2 bolts and the LH fuel rail.




101. Disconnect the fuel rail pressure (FRP) sensor electrical connector (1).




102. Remove the RH fuel injector feed pipes.




103. Remove the 2 bolts and the RH fuel rail.




104. Remove the 2 bolts and the turbocharger cooling outlet pipe.




105. Remove the left intake manifold nuts/bolts and remove the manifold.




106. Remove the right intake manifold nuts/bolts and remove the manifold.




107. Disconnect the fuel pump electrical connector.
108. Remove the 4 bolts and fuel injection pump.
109. Remove the transmission fill tube.
110. Remove the engine oil indicator tube. Refer to Oil Level Indicator and Tube Replacement (LLY, LBZ) (Oil Level Indicator and Tube Replacement (LLY, LBZ))Oil Level Indicator and Tube Replacement (LMM) (Oil Level Indicator and Tube Replacement (LMM)) .
111. Remove the transmission. Refer to Transmission Replacement .
112. Remove the engine flywheel. Refer to Engine Flywheel Replacement (Engine Flexplate/Flywheel Replacement) .
113. Remove the upper oil pan. Refer to Upper Oil Pan Replacement (Upper Oil Pan Replacement) .

Important: Remove the engine flywheel housing before installing the engine on a stand.


114. Remove the engine flywheel housing. Refer to Engine Flywheel Housing Replacement (Engine Flywheel Housing Replacement) .
115. Remove the oil pump pickup tube. Refer to Oil Pump Suction Pipe and Screen Assembly Removal (Overhaul) .
116. Remove the oil filter adapter and the oil cooler assembly replacement. Refer to Oil Filter Adapter and Oil Cooler Assembly Replacement (Service and Repair) .
117. Remove the left exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side (4.3L) ()Exhaust Manifold Replacement - Left Side (4.8L, 5.3L, 6.0L) ()Exhaust Manifold Replacement - Left Side (6.6L) () .
118. Remove the right exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side (4.3L) ()Exhaust Manifold Replacement - Right Side (4.8L, 5.3L, and 6.0L) ()Exhaust Manifold Replacement - Right Side (6.6L) () .
119. Remove the G102, G103 and G108.
120. Using J 36857 engine lift hooks, install a suitable lifting device.
The engine will have to be angled in order to remove. Use a load positioning sling to assist in angling the engine.
121. Raise the engine off the engine mounts.




122. Remove the left engine mount to engine mount frame bracket bolts.




123. Remove the left engine mount to engine bolts.
124. Remove the left engine mount bracket to frame bolts.




125. Remove the right engine mount to engine mount frame bracket bolts.




126. Remove the right engine mount to engine bolts.
127. Remove the right engine mount bracket to frame bolts.
128. Remove the engine from the vehicle.
129. Place the engine on a suitable stand.