Engine - Removal

REMOVAL

Special Tools:










1. Remove bolts (1) and the engine cover (2).
2. Disconnect the hood support struts and position hood out of the way.
3. Disconnect both negative and positive battery cables.
4. Drain cooling systemService and Repair.
5. Remove the air cleaner bodyAir Cleaner Body - Removal.
6. Recover A/C refrigerantRefrigerant System Recovery.





7. Drain engine oil.
8. Reinstall drain plug. Tighten to 50 Nm (37 ft. lbs.).





9. Remove bolts (1) and the bell housing access cover (2).





10. Install the Barring Tool (1).
11. Using the Barring Tool (1), rotate the engine and remove the torque converter bolts.
a. On manual transmission models, remove the dual mass flywheel bolts.
12. Remove the Barring Tool (1).
13. Remove the left ground strap.
14. Disconnect the transmission harness connector.
15. Remove the radiator closure panel Radiator Closure Panel - Removal.
16. Remove the fan and fan shroud Radiator Cooling Fan.
17. Disconnect the upper and lower radiator hoses and remove the radiator.
18. Remove the serpentine drive beltSerpentine Accessory Drive Belt - Removal.





19. Remove the power steering reservoir Reservoir, Power Steering Pump - Removal.
20. Remove the power steering pump Power Steering Pump - Removal.






NOTE: Illustration shown with lower radiator hose removed for clarity.

21. Remove the nuts (1) that secure the A/C suction line (3) and the A/C discharge line (4) to the A/C compressor (2).
22. Disconnect the A/C suction and discharge lines from the A/C compressor and remove and discard the O-ring seals and gaskets.
23. Install plugs in, or tape over the opened refrigerant line fittings and compressor ports.
24. Disconnect engine wiring harness connector from Totally Integrated Power Module (TIPM).
25. Remove the starter cable at the left battery and power distribution center.
26. Disconnect the intake heater connector.
27. Remove the battery negative cables to the engine block on the driver and passenger side.
28. Disconnect the generator harness wires.
29. Disconnect the block heater harness connector.
30. Disconnect the left side, engine block to frame, ground wire.






NOTE: Do not remove the elbow (1) from the turbocharger.

31. Remove the V-clamp (2) from the exhaust pipe-to-turbocharger outlet elbow connection.
32. Disconnect the heater core supply and return hoses.
33. Disconnect the fuel supply and return lines from the fuel filter housing.






NOTE: Starter, transmission, and flex plate/flywheel removed for clarity.

34. Remove the transmission collar (1).
35. Remove the engine to transmission bolts.





36. Remove the cylinder head cover (1) Cylinder Head Cover(s) - Removal.





37. Disconnect the injector wiring harness connectors to injector connections on cylinder head cover carrier gasket (3).
38. Remove the injector harness nuts to injectors (1).
39. Remove the cylinder head cover/injector wiring gasket (2).





40. Remove the EGR coolerEGR Cooler - Removal.

NOTE: Mark the location of pushrods and crossheads for reinstallation.

41. Remove the rocker arms (1), pedestals (2), and pushrods for cylinders No. 4, No 5, and No. 6.






NOTE: Extreme care should be used to keep dirt/debris from entering the fuel lines. Plastic caps should be used on the ends of the fuel lines.

42. Remove the No. 6 high pressure fuel line shield.
43. Remove the No. 5 and No. 6 high pressure fuel line.
44. Remove the HPC connector tube and nut.
45. Remove the No. 5 and No. 6 fuel injector.
46. Remove the No. 4 and No. 5 head bolts.
47. Install the front and rear engine lift bracket. Tighten to 77 Nm (57 ft. lbs).
48. Remove the two cylinder head bolts (1 and 3) according to the diagram and install the Engine Lifting Bracket (2). Tighten bolts to 105 Nm (77 ft. lbs.).
49. Attach a chain with two hooks to the engine lift brackets.
50. Remove the engine mount through bolts and nuts.
51. While keeping engine level, lift straight up out of the mounts.
52. Rotate the nose of engine upward and pull out of chassis.