Part 1

Engine Replacement Part 1

Special Tools

* CH-49736 - Hydrocarbon Injector Quick Connect Release Tool

* J-36857 - Engine Lift Bracket

For equivalent regional tools, refer to Special Tools Special Tools

Removal Procedure

Note:
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 Service and Repair

2. Remove the cooling layer. Refer to Cooling Layer Removal Cooling Layer Removal

3. Remove the cooling fan. Refer to Fan Replacement Fan Replacement

4. Remove the drive belt. Refer to Drive Belt Replacement Service and Repair





5. Remove the generator and bracket bolts (1).

6. Remove the generator (2).

7. Disconnect the generator electrical connector.

8. Remove the positive battery cable from the generator, perform the following:

1. Slide the boot down to access the terminal stud.

2. Remove the positive cable nut.

3. Remove the positive cable.





9. Remove the oil indicator tube bracket bolt (1).





10. Remove the drive belt tensioner bolt (1) and tensioner (2).





11. Remove the inlet pipe bracket bolts (1) from the generator bracket and the inlet manifold tube.





12. Remove the generator bracket nuts (1) and bolt (2) from the cylinder block. Remove the generator bracket (3).

13. If replacing the generator bracket, remove the idler pulleys (4) and transfer to the new generator bracket.

14. If equipped, remove the auxiliary generator. Refer to Auxiliary Generator Replacement (KD9) Auxiliary Generator Replacement (KD9)





15. Remove the auxiliary generator bracket bolt (1) and bracket (2) , if equipped.

16. If equipped with a dual generator system, remove the bolt from the left side idler pulley and remove the idler pulley.

17. Disconnect the air conditioning (A/C) compressor clutch electrical connector.

18. Disconnect the A/C cut out switch electrical connector.





19. Remove the A/C compressor bolts (1).

20. Remove the A/C compressor (2).





21. Remove the power steering pump mounting bolts (6).

22. Position the power steering pump aside and secure.





23. Remove the air conditioning compressor bracket nuts (1).

24. Remove the air conditioning compressor bracket bolts (2).

25. Remove the air conditioning compressor bracket (3).





26. Remove the fuel pressure service valve bolt (1) and position the valve (2) aside.





27. Remove the turbocharger coolant feed pipe retainer bolt (1).

28. Slide the hose clamp (4) upward and remove the turbocharger coolant feed pipe (2) and hose (3) from the engine.





29. Disconnect the engine coolant temperature sensor electrical connector (1).

30. Remove the turbocharger coolant feed hose (2).

31. Remove the oil fill tube bolt (3); the oil fill tube retainer bracket bolt (4) and the oil fill tube (5).





32. Disconnect the turbocharger coolant return hose (1) at the thermostat bypass pipe (3).

33. Remove the thermostat bypass bolts (2) at the water pump and remove the thermostat bypass pipe (3).





34. Remove the thermostat housing crossover bolts (1) and nuts (2).

35. Remove the thermostat housing crossover pipe (4) and gaskets (3).





36. Disconnect the intake air heater (IAH) and throttle body electrical connectors (1).





37. Disconnect the engine harness electrical connector (1) from the manifold absolute pressure (MAP) sensor (2).





38. Disconnect the positive cable (2) from the IAH by performing the following:

1. Reposition the positive battery cable boot.

2. Remove the positive battery cable nut (1) at the IAH.

3. Remove the positive battery cable from the IAH stud.

39. Remove the throttle body and intake air heater fasteners.

40. Remove the throttle body and intake air heater from the vehicle.

41. Remove the heater inlet pipe clamps and fasteners. Remove heater inlet pipe.

42. Remove the upper portion of the transmission fill tube.





43. Remove the EGR bracket bolts (1) and bracket (2).

44. Remove the left side fuel return hose connections from the injectors.





45. Reposition the positive crankcase ventilation oil separator hose (oil separator to oil pan) clamp.

46. Remove hose from separator.

47. Remove positive crankcase ventilation oil separator bolts.





48. Remove the crankcase depression regulator valve bolts (1).

49. Remove the oil separator, hose and crankcase regulator as an assembly (2).





50. Remove the turbocharger air inlet adaptor clamp (1).

51. Remove the turbocharger air inlet adaptor (2).





52. Remove the intake manifold tube bolts (1).

53. Remove the engine wiring harness clip from the intake manifold tube.

54. Remove the intake manifold tube (2).

55. Remove and discard the 2 metal EGR gaskets from the EGR valve.

56. Remove and discard the O-ring seal from the center intake manifold.

57. Remove the right exhaust pipe. Refer to Exhaust Manifold Outlet Pipe Replacement - Right Side (LGH) Exhaust Manifold Outlet Pipe Replacement - Right Side

58. Remove the left exhaust pipe. Refer to Exhaust Manifold Outlet Pipe Replacement - Left Side (LGH) Exhaust Manifold Outlet Pipe Replacement - Left Side





59. Remove the 2 rear EGR cooler valve retaining bolts (1).





60. Remove the 2 bolts and the EGR cooler bracket (1).

61. Disconnect the engine wiring harness electrical connector from the turbocharger vane position sensor.

62. Disconnect the engine wiring harness electrical connector from the turbocharger vane control solenoid valve.

63. Disconnect the engine wiring harness electrical connector from the glow plug module.

64. Disconnect the positive battery cable from the glow plug control module.

65. Remove the glow plug control module bolts.

66. Remove the glow plug control module.

67. Disconnect the EGR solenoid electrical connector.

68. Disconnect the EGR temperature sensor electrical connector.

69. Remove the EGR and cooler assembly hold down fasteners.

70. Remove the EGR valve and EGR cooler tube as an assembly.





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

71. Reposition the turbocharger coolant feed pipe clamp (1) and remove the hose from the turbocharger pipe.

72. Remove the turbocharger coolant return hose/pipe. Refer to Turbocharger Coolant Hoses/Pipes Replacement (Feed - LGH) Turbocharger Coolant Hoses/Pipes Replacement (Feed)Turbocharger Coolant Hoses/Pipes Replacement (Return - LGH) Turbocharger Coolant Hoses/Pipes Replacement (Return)

73. Remove the glow plug control module bracket bolts.

74. Remove the glow plug control module bracket.





75. Remove the turbocharger oil feed pipe banjo bolt and washer. Discard the eye bolt and washer.





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





77. Disconnect the turbocharger charged air temperature sensor.

78. Remove the turbocharger bolts.

79. Remove the turbocharger, with the oil feed return pipes.

80. Remove and discard the turbocharger oil return pipe gasket at the flywheel housing.

81. Remove the center intake fasteners and center intake from the vehicle.

82. Remove the glow plug retaining nuts and glow plug connectors.

83. Disconnect fuel injector and engine sensor connectors.

84. Remove engine ground and strap fasteners and engine grounds from engine.

85. Position the engine wiring harness over to the left side of engine.

86. Remove the main fuel feed and return pipe fasteners. Disconnect hoses from the pipes.

87. Remove the main fuel feed and return pipes together as an assembly.

88. Disconnect the fuel return hose connectors from the remaining injectors.

89. Remove the fuel return hose assembly from the vehicle.

90. Remove the injector fuel feed pipes.

91. Remove the fuel injectors.

92. Remove the high pressure fuel feed pipes from the injection pump and fuel rails.

93. Remove the indirect fuel injector fasteners (1, 2).





94. Remove the indirect fuel injector retainer (1) from the fitting.

95. Remove the indirect fuel injector (2) using the CH-49736 - tool.

96. Remove the injector nozzle from the exhaust pipe.

97. Remove the right and left hand pump to rail high pressure lines.





98. Remove the rail to rail high pressure pipe.





99. Remove the 2 bolts and the right fuel rail.

100. Remove the left fuel rail shield bolts and shield.





101. Remove the 2 bolts and the left fuel rail.

102. Remove the fan pulley bolts and nuts and fan pulley from engine.

103. Remove the fuel feed pipe (pipe to indirect injector) eye bolt and washer. Discard bolt and washer.

104. Remove fuel feed pipe from the injection pump.





105. Remove the camshaft gear access hole plug (1).





Note:
The fuel pump must be correctly timed to the camshaft gear.

106. Rotate the crankshaft until the fuel injection pump gear timing marks are aligned with camshaft gear timing marks.

107. Remove the 4 bolts and fuel injection pump.





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





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

110. Remove the left hand exhaust manifold bolts. Remove manifold studs and then manifold from the engine.

111. Remove the 4 left hand glow plugs from the engine.

112. Raise the vehicle.

113. Remove the oil filter adapter and the oil cooler assembly. Refer to Oil Filter Adapter and Oil Cooler Assembly Replacement Oil Filter Adapter and Oil Cooler Assembly Replacement

114. Remove the 2 nuts and disconnect the relay rod from the pitman and idler arms. Reposition relay rod down and out of the way for oil pan clearance.

115. Remove the engine splash shield bolts and shield from vehicle.

116. Remove the starter motor.

117. Remove the transmission torque converter bolts.

Note:
Leave the 3 upper transmission bell housing studs installed until the engine lift and brackets are attached.

118. Remove the PCV oil separator hose from the oil pan.

119. Remove the transmission oil cooler line bracket from the oil pan.