Engine - Removal

3.0L COMMON RAIL DIESEL ENGINE REMOVAL





1. Disconnect negative battery cable.
2. Drain cooling system.
3. Evacuate air conditioning.
4. Remove the strut tower support (2).




5. Remove engine cover (3).
6. Remove air cleaner housing Air Cleaner Housing - Removal.




7. Remove lower catalytic converter to upper catalytic converter clamp (1) behind right cylinder head.
8. Raise and support the vehicle.
9. Remove front splash shield.
10. Drain power steering at cooling fan, cap lines and set aside.




11. Remove catalytic converter clamp from exhaust pipe (2).
12. Remove transfer case splash shield.
13. Disconnect the front exhaust pipe (2) at muffler (3).
14. Remove the catalytic converter and front exhaust pipe (2).




15. Paint mark the flex plate to torque converter relation and remove the torque converter bolts (1) through the access hole.




16. Support the transmission with a transmission jack and remove the transfer case cross over bolts from frame.
17. Carefully lower the transmission enough to gain access to the upper transmission to engine mounting bolts, and remove accessible bolts.
18. Raise transmission, install the transfer case cross over bolts, and remove transmission jack.
19. Disconnect the transmission wiring harness at transmission and route wiring harness toward the starter.
20. Remove remaining transmission to engine bolts.
21. Disconnect the engine ground strap (1) in front of the starter (2).




22. Loosen both engine mount through bolts.
23. Remove the lower radiator hose.
24. Remove the front axle housing Removal.
25. Lower the vehicle.
26. Remove the front grille and radiator upper core support. Remove the hood latch and position aside.
27. Remove the front core support brackets.
28. Remove the charge air inlet hose (5).
29. Remove the charge air outlet hose (5).
30. Disconnect the power steering reservoir hose to pump, at the reservoir.
31. Disconnect the suction/discharge lines at the condenser and accumulator.
32. Disconnect the transmission cooler (3) and power steering cooler lines (4) at the coolant module.
33. Position the radiator (1) deflectors aside and remove coolant module to core support fasteners.
34. Remove cooler module assembly.




35. Remove the battery (4) and tray.
36. Remove the power distribution center (PDC) (1) from the bracket and remove the bracket.
37. Disconnect the PCM (3) and route the engine wiring harness on top of the engine.
38. Route engine wiring aside and disconnect the starter wiring.
39. Unplug air conditioning (AC) compressor wiring at compressor, route the transmission harness forward, and place the harness on top of the engine.




40. Disconnect the generator wiring harness, and position aside.
41. Disconnect the vacuum hose at the vacuum pump, and set aside.
42. Disconnect the wiring harness connectors from the PDC.
43. Disconnect the heater hose (2) at cooler tube on the right cylinder head.
44. Disconnect the coolant by-pass hose (2) at the cooler tube on the right cylinder head.
45. Disconnect the coolant hose, at the outer housing, by the generator.
46. Disconnect the A/C lines (1) at the expansion valve.
47. Remove the engine cover mounting bracket.
48. Remove the transmission oil level indicator tube retaining bolt.




49. Loosen front axle vent tube from wiring harness and position aside.
50. Disconnect the fuel lines from the fuel pipe using special tool #6507.




51. Remove upper turbocharger heat shield.
52. Connect engine lift chain to engine lift fixtures.
53. Support the transmission with a floor jack.
54. Lift the weight of the engine off of the engine mounts (1,2).
55. Remove right engine mount from engine.
56. Remove left engine mount from engine.
57. Remove engine from vehicle.