Removal
REMOVAL
Special Tool(s)
Material
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the battery ground cable.
3. Remove the A/C condenser assembly.
4. Remove the front bumper.
5. Remove the radiator grille support.
6. Remove the bolts, disconnect and remove the air bag sensor. Position the headlamp wiring harness aside.
7. NOTE: Mark the latch before removal.
Remove the bolts and hood latch.
8. NOTE: RH shown, LH similar.
Remove the eight bolts and the upper radiator support.
9. NOTE: LH shown, RH similar.
Remove the 12 bolts and lower radiator support.
10. Remove the intake manifold.
11. Remove the RH fan stator stand-off. Remove the bolt and position the cable aside.
12. Disconnect the A/C electrical connector.
13. Disconnect the A/C pressure switch and remove the A/C manifold from the tee block.
^ Remove and discard the O-ring seals.
^ Cap or plug the A/C openings as needed.
14. Remove the bolts and A/C compressor.
15. Disconnect the heater hose. Position the heater hose and tube aside.
16. Remove the bolt and idler pulley.
17. Disconnect the engine coolant fill hose from the retaining clip. Loosen the clamp and remove the engine coolant fill hose.
18. Disconnect the vacuum pump hose and remove the engine coolant fill hose clip.
19. NOTE: The bolt behind the pulley is accessed thorough the pulley with an extension and a short socket.
Remove the bolts and the vacuum pump.
20. Remove the power steering upper mounting bolts.
21. Remove the LH fan stator stand-off.
22. NOTE: The front bolt will remain in the power steering pump.
Remove the bolts and position the power steering pump aside.
23. Remove the lower radiator hose.
24. Disconnect the fuel lines.
25. Disconnect the Crankshaft Position (CKP) sensor electrical connector and retaining clips.
26. Disconnect the Injection Control Pressure (ICP) sensor electrical connector. Disconnect the glow plug electrical connector and wire retainers.
27. Disconnect the Camshaft Position (CMP) sensor electrical connector and retaining clips.
28. Disconnect the electrical connector and wire retainers at the transmission.
29. Disconnect the glow plug module electrical connectors.
30. CAUTION: Do not use power tools when removing the nut.
Position back the boot and disconnect the B+ wire.
31. Disconnect the exhaust back pressure sensor electrical connector and pushpin retainer.
32. Disconnect the LH glow plug electrical connector.
33. Disconnect the two electrical connectors.
34. Disconnect the two Powertrain Control Module (PCM) electrical connectors and position the engine wiring harness aside.
35. Remove the bolts and the oil filter assembly.
36. Remove the retaining nut and remove the transmission cooling tubes off the stud.
37. Remove the retaining clips from the transmission tubes.
38. Using the special tool, disconnect transmission cooler tubes
39. Remove the torque converter cover.
40. Remove and discard the torque converter nuts.
41. Disconnect the block heater electrical connector.
42. Remove the retaining nut and position the cable bracket aside.
43. Remove the starter solenoid protective cap.
44. Disconnect the starter motor electrical connections.
45. Remove the bolts and the starter motor.
46. NOTE: Right side shown, left side similar.
Remove the cylinder block drain plugs and drain the coolant from the block.
47. NOTE: Apply clean engine oil to the O-ring seal prior to installing.
Install the cylinder block drain plugs.
48. NOTE: Left side shown, right side similar.
Remove the motor mount nuts.
49. Remove the lower engine-to-transmission bolts.
50. Remove the mounting bolts from the lifting bracket and remove the tubes
51. Disconnect the glow plug wire retainer. Remove the retaining nut and the oil indicator and tube.
^ Remove and discard the O-ring seal.
52. Disconnect the exhaust back pressure tube at the exhaust manifold.
53. Remove the retaining nuts and glow plug module.
54. NOTE: Power stud removed for clarity.
Remove the retaining nuts and the glow plug module mounting bracket.
55. NOTE: Mark the location of the studs prior to removal.
Remove the bolts and the LH valve cover.
^ Remove the valve cover gasket.
^ Cover the cylinder head after the valve cover is removed.
56. Remove the ICP sensor.
^ Plug or cap the opening as needed.
57. NOTE: Do not tighten the bolts at this time.
Install the special tools.
58. Remove the turbocharger exhaust pipe.
59. Remove the factory-installed engine lifting bracket.
60. Install the special tool.
61. Install the engine lifting attachment and lifting crane.
62. Remove the oil pan drain plug and drain the engine oil.
63. NOTE: It may be necessary to raise the engine for oil pan removal. Disconnect the linkage from the engine lifting attachment to raise the engine.
NOTE: The oil pan bolts must be reinstalled in their original positions. Mark the location of the longer bolts to aid in installation.
Remove the bolts and position back the oil pan until the oil pickup tube bolts are accessible.
64. Remove the bolts and let the oil pickup tube go into the oil pan. Remove the oil pan.
65. Remove the press-in-place gasket and discard.
66. Remove and discard the oil pickup tube O-ring seal.
67. Position a suitable transmission jack under the transmission.
68. Remove the upper engine-to-transmission bolts.
69. Raise the engine. Remove the four bolts and LH motor mount.
70. NOTE: Front bolts shown, rear bolts similar.
Remove the bolts and the RH motor mount.
71. NOTE: The engine must be moved to the driver side for removal.
Remove the engine from the vehicle.