Removal Procedure
- Recover the refrigerant. REFRIGERANT RECOVERY AND RECHARGING
- Relieve the fuel system pressure. Fuel Pressure Relief
- Drain the coolant. Refer to Cooling System Draining and Filling (L3B Static Fill) , or Cooling System Draining and Filling (L3B GE 47716)
- Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
- Drain the engine oil. Engine Oil and Oil Filter Replacement
- Remove the front tire and wheel assemblies. Tire and Wheel Removal and Installation
- Remove the oil fill cap.
Intake Manifold Cover Bolt (1) - Remove [2x]
- Lift up on the front of the intake manifold cover (2).
Intake Manifold Cover (1) @ Upper Intake Manifold Bracket (2) - Remove
- Install the oil fill cap.
Intake Manifold Cover Bolt (1) - Remove
Intake Manifold Cover Insulator (1) - Remove
Evaporative Emission Canister Purge Tube (1) - Remove - Plastic Collar Quick Connect Fitting Service
Air Cleaner Outlet Duct Clamp (1) - Loosen [2x]
- Positive Crankcase Ventilation Tube (3) - Disconnect -Plastic Collar Quick Connect Fitting Service
Wiring Harness Retainer (1) @ Air Cleaner Assembly - Remove [4x]
- Electrical Connector (4) - Disconnect [2x]
- Remove the ground wire on the frame support.
Air Cleaner Outlet Duct (1) - Remove
- If replacing air cleaner outlet duct transfer parts as necessary.
Air Cleaner Bolt (1) - Remove
Air Cleaner Assembly (1) - Remove
Positive Crankcase Ventilation Tube (4) - Disconnect
Retainer (1) @ Upper Intake Manifold Bracket (2) - Unclip [2x]
Electrical Connector (1) - Disconnect [5x]
- Wiring Harness (2) - Reposition
Upper Intake Manifold Cover Nut (1) - Remove [2x]
- Radiator Surge Tank Inlet Hose Clip (2) @ Upper Intake Manifold Bracket (3) - Remove
Upper Intake Manifold Cover Nut (1) - Remove [2x]
- Upper Intake Manifold Bracket (2) - Remove
Place shop cloths beneath the radiator surge tank inlet hose connection points to absorb any potential coolant spillage.
- Radiator Surge Tank Inlet Hose Clamp (1) - Disengage [3x] - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Surge Tank Inlet Hose (2) - Remove
Heater Inlet Hose Clamp (2) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Heater Inlet Hose (3) @ Exhaust Manifold Outlet Pipe - Remove
Heater Outlet Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Heater Outlet Hose (2) @ Heater Outlet Pipe - Remove
- NOTE:
The radiator, condenser and charge air cooler will be removed together with the engine and cradle.
Remove the front 3 radiator air upper baffle retainers (1).
- Radiator Air Upper Baffle (2) - Reposition
Wiring Harness Retainer (1) - Remove
- Radiator Upper Bracket Bolt (3) - Remove [4x]
- Radiator Upper Bracket (2) - Remove [2x]
Air Conditioning Compressor Hose Nut (1) - Remove
- Air Conditioning Evaporative Connector Hose/Tube and Compressor Hose (2) @ Air Conditioning Refrigerant Heat Exchanger - Remove
- Air Conditioning Evaporator Thermal Expansion Valve Seal (3) - Remove and DISCARD
- Air Conditioning Evaporator Tube Clip Bracket Bolt (4) - Remove
- Position the air conditioning refrigerant heat exchanger out of the way.
Air Conditioning Condenser Hose Nut (1) @ Air Conditioning Condenser - Remove
- Air Conditioning Condenser Tube Clip (2) - Remove
Air Conditioning Evaporative Connector Hose/Tube and Compressor Hose (1) @ Air Conditioning Condenser - Remove
- Air Conditioning Compressor and Condenser Hose Seal (2) - Remove and DISCARD
Air Conditioning Refrigerant Heat Exchanger (1) @ Air Conditioning Condenser - Remove
- Air Conditioning Condenser Hose Seal (2) - Remove and DISCARD
Unfasten the radiator inlet hose clip (1), and position the radiator inlet hose (2) out of the way.
Disconnect the electrical connectors. (1) [3x]
Air Conditioning Compressor Hose Nut (1) - Remove
Air Conditioning Evaporative Connector Hose/Tube and Compressor Hose (1) @ Air Conditioning Compressor - Remove
- Air Conditioning Compressor and Condenser Hose Seal (2) - Remove and DISCARD
- Air Conditioning Compressor Hose Seal (3) - Remove and DISCARD
- Maneuver the air conditioning evaporative connector hose/tube and compressor hose out of the engine compartment.
Battery Distribution Engine Compartment Fuse Block Cover (1) - Remove
- Battery Positive Cable Nut (6) - Remove
- Battery Positive Cable (7) - Remove
- Auxiliary Generator Battery Jumper Cable Nut (5) - Remove
- Auxiliary Generator Battery Jumper Cable (8) - Remove
- Engine Wiring Harness Terminal Nut (4) - Remove
- Engine Wiring Harness Terminal Nut (3) - Remove
- Engine Wiring Harness (9) - Remove [2x]
- Forward Lamp Wiring Harness Terminal Nut (2) - Remove [2x]
- Forward Lamp Wiring Harness (10) - Remove [2x]
Retaining Tab (1) - Disengage [2x]
- Battery Distribution Engine Compartment Fuse Block (2) - Remove
Battery Positive Cable Nut (1) - Remove
- Auxiliary Generator Battery Jumper Cable (2) - Remove
- Battery Positive Cable (3) - Remove
Retainer (1) - Disengage [2x]
- Engine Wiring Harness Fuse Block Cover (2) - Remove
Engine Wiring Harness Junction Block Bolt (1) - Remove
- Retaining Tab (2) - Disengage [4x]
- Engine Wiring Harness Junction Block (3) - Remove
Disengage the 2 retaining covers (2), and remove the 2 electrical connectors (1).
Disengage the 3 retaining tabs (1) from the body wiring harness junction block bracket (3) and remove the engine wiring harness fuse block bracket (2).
Body Wiring Harness Fuse Block Bracket Bolt (1) - Remove [2x]
- Body Wiring Harness Junction Block Bracket (2) - Remove
Disconnect the 3 electrical connectors (1) from the engine control module.
- Raise and support the vehicle. Lifting and Jacking the Vehicle
Front Bumper Fascia Center Air Deflector Screws (1) - Remove [10x]
Front Bumper Fascia Center Air Deflector Screws (1) - Remove [3x]
Front Bumper Fascia Center Air Deflector Screw (1) - Remove [6x]
- Front Bumper Fascia Center Air Deflector Bolt (2) - Remove [5x]
- Front Bumper Fascia Center Air Deflector Retainer (3) - Remove [2x]
Pull the front bumper fascia center air deflector (1) rearward and down from the front bumper fascia.
Front Bumper Fascia Center Air Deflector Bolt (1) - Remove [5x]
- Front Bumper Fascia Air Deflector Retainer (2) - Remove [2x]
Front Wheelhouse Liner Bolt (1) - Remove
- Engine Front Splash Shield Retainer (2) - Remove [2x]
- Engine Front Splash Shield Bolt (3) - Remove
Front Wheelhouse Liner Bolt (3) - Remove
- Engine Front Splash Shield Retainer (2) - Remove [2x]
- Engine Front Splash Shield Bolt (1) - Remove
Front Compartment Air Deflector Bolt (1) - Remove [4x]
- Front Compartment Air Deflector (2) - Remove
Radiator Air Front Lower Baffle Retainer (1) - Remove [3x]
Radiator Air Front Lower Baffle (1) - Remove
Rear Tire Front Air Deflector Bolt (1) - Remove [2x]
- Rear Tire Front Air Deflector- Left Side (2) - Remove
Rear Wheelhouse Liner Bolt (1) - Remove
- Underbody Rear Air Deflector Nut (2) - Remove [3x]
- Underbody Rear Air Deflector Bolt (3) - Remove [3x]
- Underbody Rear Air Deflector Nut (4) - Remove [2x]
- Underbody Rear Air Deflector- Left Side (5) - Remove
Rear Tire Front Air Deflector Bolt (1) - Remove [2x]
- Rear Tire Front Air Deflector- Right Side (2) - Remove
Rear Wheelhouse Liner Bolt (1) - Remove
- Underbody Rear Air Deflector Bolt (2) - Remove [3x]
- Underbody Rear Air Deflector Nut (3) - Remove [3x]
- Underbody Rear Air Deflector Nut (4) - Remove [2x]
- Underbody Rear Air Deflector- Right Side (5) - Remove
Floor Panel Number 4 Cross Bar Reinforcement Bolt (2) - Remove [6x]
- Floor Panel Number 4 Cross Bar Reinforcement (1) - Remove
Catalytic Converter Nut (1) - Remove [2x]
Exhaust Muffler (1) @ Exhaust Intermediate Pipe Insulator- Left Side (2) - Separate
- Exhaust Muffler (1) @ Exhaust Rear Muffler Insulator- Left Side (3) - Separate
Exhaust Muffler (1) @ Exhaust Intermediate Pipe Insulator- Right Side (2) - Separate
- Exhaust Muffler (1) @ Exhaust Rear Muffler Insulator- Right Side (3) - Separate
- {If equipped} Electrical Connector @ Exhaust Control Valve Actuator - Disconnect
Exhaust Muffler (1) - Remove
- Catalytic Converter Gasket (2) - Remove and DISCARD
Front Axle Propeller Shaft Heat Shield Bolt (1) - Remove
- Front Axle Propeller Shaft Heat Shield Stud (2) - Remove
- Front Axle Propeller Shaft Heat Shield (3) - Remove
Exhaust Heat Shield Bolt (1) - Remove [6x]
- Exhaust Intermediate Underbody Heat Shield (2) - Remove
Floor Panel Number 2 Cross Bar Reinforcement Bolt (1) - Remove [4x]
- Floor Panel Reinforcement (2) - Remove
Transmission Mount Bracket Bolt (1) - Remove [4x]
- NOTE:
The transmission mount bolt is retained in the mount, loosen the bolt to disengage the threads and remove the mount and bolt as an assembly.
Transmission Mount Bolt (1) - Remove
- Transmission Mount (2) - Remove
Transfer Case Front Output Shaft Boot Clamp (1) @ Transfer Case Front Output Shaft - Remove and DISCARD
- Release the transfer case front output shaft boot (2) from the groove in the transfer case front output shaft.
Mark the relationship between the front axle propeller shaft (2) and the front differential carrier flange with a grease pencil.
- Front Axle Propeller Shaft Bolt (1) - Remove [6x]
- Front Axle Propeller Shaft Washer (3) - Remove [3x]
Front Axle Propeller Shaft (1) - Remove
Inspect the transfer case front output shaft boot (1), if damage is found, remove and DISCARD the transfer case front output shaft boot clamp (2) and the transfer case front output shaft boot (1).
Transmission Fluid Cooler Pipe Nut (1) - Remove
- Transmission Fluid Cooler Inlet and Outlet Pipe (2) @ Transmission Cooler Bypass Valve - Remove
Transmission Fluid Cooler Pipe Nut (1) - Remove
- Transmission Fluid Cooler Inlet and Outlet Pipe (2) @ Transmission Cooler Bypass Valve - Remove
Transmission Fluid Cooler Thermal Bypass Valve Bolt (1) - Remove
- Transmission Cooler Bypass Valve (2) - Remove
Transmission Fluid Cooler Thermal Bypass Valve Gasket (1) - Remove and DISCARD [4x]
Automatic Transmission Fluid Cooling Heat Exchanger Inlet Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Automatic Transmission Fluid Cooling Heat Exchanger Inlet Hose (2) @ Automatic Transmission Fluid Cooling Exchanger - Remove
- Automatic Transmission Fluid Cooling Heat Exchanger Outlet Hose Clamp (3) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Automatic Transmission Fluid Cooling Heat Exchanger Outlet Hose (4) @ Automatic Transmission Fluid Cooling Exchanger - Remove
Transmission Fluid Cooler Pipe Connector Bolt (1) - Remove [2x]
- Transmission Fluid Cooler Inlet and Outlet Pipe (2) @ Automatic Transmission Fluid Cooling Exchanger - Remove
Transmission Fluid Cooler Pipe Seal (1) - Remove and DISCARD [2x]
Automatic Transmission Fluid Cooling Exchanger Bolt (1) - Remove [3x]
- Automatic Transmission Fluid Cooling Exchanger (2) - Remove
- Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off.
- Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off.
- Using suitable straps or chains, secure the vehicle to the hoist arms.
Propeller Shaft Hub Clamp (1) - Remove and DISCARD
Mark (2) the relationship of the propeller shaft to the rear differential flange using a paint pen.
- Rear Propeller Shaft Nut (3) - Remove [3x]
- Rear Propeller Shaft Bolt (1) - Remove [3x]
- Support and secure the propeller shaft to a suitable hydraulic jack stand.
Propeller Shaft Bearing Support Bolt (1) - Remove [2x]
Propeller Shaft (1) - Remove
- Using suitable straps or chains, secure the front of vehicle to the hoist arms.
- NOTE:
Left side shown, right side similar.
Front Tire Front Air Deflector Bolt (1) - Remove [8x]
- Front Tire Front Air Deflector (2) - Remove [2x]
- NOTE:
Left side shown, right side similar.
Engine Front Splash Shield Bolt (1) - Remove [10x]
- Engine Front Splash Shield Retainer (2) - Remove [2x]
- Engine Front Splash Shield (3) - Remove [2x]
- NOTE:
Left side shown, right side similar.
Front Bumper Fascia Bolt (1) - Remove [6x]
- Front Wheelhouse Liner Bolt (2) - Remove [10x]
- Front Wheelhouse Liner Retainer (3) - Remove [2x]
- NOTE:
Left side shown, right side similar.
Front Wheelhouse Liner Bolt (1) - Remove [4x]
- Front Wheelhouse Liner Retainer (2) - Remove [6x]
- Front Wheelhouse Liner (3) - Remove [2x]
Electronic Transmission Range Selector Manual Park Release Cable Clamp Bolt (1) - Remove
- Electronic Transmission Range Selector Manual Park Release Cable (2) @ Transmission - Remove
Unclip the electronic transmission range selector manual park release cable (1) retainer from the electronic transmission range selector manual park release cable bracket.
- Remove the electronic transmission range selector manual park release cable (2) from the transmission.
Front Crossmember Brace Nut (1) - Remove [4x]
- Front Crossmember Brace (2) - Remove
Front Crossmember Brace Bolt- Right Side (1) - Remove [4x]
- Front Crossmember Brace Nut- Right Side (2) - Remove
- Front Crossmember Brace- Right Side (3) - Remove
Front Crossmember Brace Bolt- Left Side (1) - Remove [4x]
- Front Crossmember Brace Nut- Left Side (2) - Remove
- Front Crossmember Brace- Left Side (3) - Remove
- NOTE:
Left side shown, right side similar.
Front Stabilizer Shaft Link Nut- Lower (1) - Remove [2x]
- NOTE:
Left side shown, right side similar.
Front Stabilizer Shaft Link (1) @ Stabilizer Shaft - Remove [2x]
- NOTE:
Left side shown, right side similar.
Front Wheel Speed Sensor Bolt (1) - Remove [2x]
- Front Wheel Speed Sensor (2) - Remove [2x]
- NOTE:
Left side shown, right side similar.
Front Brake Caliper Bolt (2) - Remove [4x]
- Remove the brake caliper and support with heavy mechanics wire. (1) [2x]
- NOTE:
Left side shown, right side similar.
Steering Knuckle Nut (1) - Remove [4x]
- Steering Knuckle Bolt (2) - Remove [4x]
Disconnect the steering gear electrical connectors. (1)
- Disconnect electrical connectors at engine mounts.
Wiring Harness Retainer (1) - Disengage [6X]
- Turn the wheels of the vehicle back to the straight ahead position.
- Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off.
- Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off.
- Touch a metal ground point in order to remove your body's static charge before servicing any electronic component; especially after sliding across the vehicle seat.
- Do not touch exposed terminals. Terminals may connect to circuits susceptible the ESD damage.
- Do not allow tools to contact exposed terminals when servicing connectors.
- Do not remove components from their protective packaging until required to do so.
- Avoid the following actions unless required by the diagnostic procedure:
- Jumpering or grounding of the components or connectors.
- Connecting test equipment probes to components or connectors. Connect the ground lead first when using test probes.
- Ground the protective packaging of any component before opening. Do not rest solid-state components on metal workbenches, or on top of TVs, radios, or other electrical devices.
- The steering column
- The intermediate shaft (s)
- The steering gear
- With the wheels of the vehicle in the straight ahead position, LOCK the steering column.
- Separate the mid lower intermediate steering shaft from the intermediate steering shaft by pushing the lower portion of the mid lower intermediate shaft upward and rearward along the axis of the upper portion of the mid lower intermediate steering shaft.
Intermediate Steering Shaft Lower Bolt (1) @ Electric Belt Drive Rack and Pinion Steering Gear - Remove
Intermediate Steering Shaft (1) @ Electric Belt Drive Rack and Pinion Steering Gear - Separate
Disconnect the electrical connector. (1)
- Release the retainers. (2)
- Disconnect the transmission vent hose from the engine.
Lower the vehicle until the powertrain (1) rests lightly on the GE-52200-A Propulsion System Lift (2).
- Secure the powertrain (1) to the GE-52200-A Propulsion System Lift (2) using straps and binders around the transmission and cradle.
Drivetrain and Front Suspension Cradle Front Bolt (1) - Remove [4x]
- Drivetrain and Front Suspension Cradle Rear Bolt (2) - Remove [2x]
- Ensure when raising the body the following items are clear from the frame:
- Vacuum lines
- Steering knuckles
- Electrical wiring harnesses
- With the aid of the assistant raise the body from the drivetrain and front suspension cradle.
- CAUTION:
DO NOT use air tools to remove the wheel drive shaft nut. Damage to the wheel drive shaft threads could occur. Use hand tools only.
Front Wheel Drive Shaft Nut (1) - Remove and DISCARD
Install the DT-45859 Axle Remover (1) to the front wheel hub and secure with 3 wheel nuts (2) hand tightened.
- Using the DT-45859 Axle Remover (1), release the front wheel drive half shaft from the front wheel hub.
- Remove the 3 wheel nuts (2) and the DT-45859 Axle Remover (1) from the front wheel hub.
Steering Linkage Outer Tie Rod Nut (2) - Loosen
- Using CH-42188-B Ball Joint Separator (1) separate the steering linkage outer tie rod (3) from the steering knuckle.
- CH-42188-B Ball Joint Separator (1) - Remove
- Steering Linkage Outer Tie Rod Nut (2) - Remove
Install the DT-45341 Rear Wheel Drive Shaft Removal Tool (1), GE-47829 Slide Hammer Extension (3) and GE-02619-A Slide Hammer (4) to the front wheel drive half shaft (2).
- Release the front wheel drive half shaft (2) from the front wheel drive intermediate shaft.
- Remove the GE-02619-A Slide Hammer (4), GE-47829 Slide Hammer Extension (3) and DT-45341 Rear Wheel Drive Shaft Removal Tool (1) from the front wheel drive half shaft (2).
Front Wheel Drive Half Shaft (1) - Remove
Front Wheel Drive Intermediate Shaft Retaining Ring (2) - Remove and DISCARD
- Front Wheel Drive Intermediate Shaft Seal (1) - Remove and DISCARD
Engine Mount Bracket Bolt (1) - Remove and DISCARD [4x]
- Engine Mount Bracket (2) - Remove
Front Wheel Drive Intermediate Shaft Bracket Bolt (2) - Remove [3x]
- Front Wheel Drive Intermediate Shaft Bracket (1) - Remove
- Thoroughly clean and inspect the front wheel drive intermediate shaft bracket for damage.
- If damaged, replace the front wheel drive intermediate shaft bracket.
Attach the DT - 44467 Output Shaft Assembly Remover/Installer (1) to the shaft.
- Attach the GE-6125-1B Slide Hammer (2) to the DT-44467 Output Shaft Assembly Remover/Installer (1).
- Use the tools to remove the Front Wheel Drive Intermediate Shaft (3) from the front differential carrier.
- Front Wheel Drive Intermediate Shaft (3) - Remove
- Front Wheel Drive Intermediate Shaft Retaining Ring (4) - Remove and DISCARD
- CAUTION:
DO NOT use air tools to remove the wheel drive shaft nut. Damage to the wheel drive shaft threads could occur. Use hand tools only.
Front Wheel Drive Shaft Nut (1) - Remove and DISCARD
Install the DT-45859 Axle Remover (1) to the front wheel hub and secure with 3 wheel nuts (2) hand tightened.
- Using the DT-45859 Axle Remover (1), release the front wheel drive half shaft from the front wheel hub.
- Remove the 3 wheel nuts (2) and the DT-45859 Axle Remover (1) from the front wheel hub.
Steering Linkage Outer Tie Rod Nut (1) - Loosen
- Using CH-42188-B Ball Joint Separator (2) separate the steering linkage outer tie rod (3) from the steering knuckle.
- CH-42188-B Ball Joint Separator (2) - Remove
- Steering Linkage Outer Tie Rod Nut (1) - Remove
- Steering Linkage Outer Tie Rod @ Steering Knuckle - Separate
Install the DT-45341 Rear Wheel Drive Shaft Removal Tool (1), GE-47829 Slide Hammer Extension (3) and GE-02619-A Slide Hammer (4) to the front wheel drive half shaft (2).
- Release the front wheel drive half shaft (2) from the front wheel drive intermediate shaft.
- Remove the GE-02619-A Slide Hammer (4), GE-47829 Slide Hammer Extension (3) and DT-45341 Rear Wheel Drive Shaft Removal Tool (1) from the front wheel drive half shaft (2).
Partially remove the front wheel drive half shaft (1) from the front differential carrier.
- Install the DT-51504 Seal Protector (2) into the front axle shaft seal.
Front Wheel Drive Half Shaft (1) - Remove
Front Wheel Drive Shaft Retaining Ring (2) @ Front Wheel Drive Half Shaft (1) - Remove and DISCARD
Retainer Spring (1) - Release
- Charge Air Cooler Inlet Air Tube (2) @ Turbocharger (3) - Remove
Retainer Spring (1) - Release
- Charge Air Cooler Outlet Air Tube (2) @ Throttle Body (3) - Remove
- CAUTION:CAUTION:
The use of excessive force may damage the threads in the exhaust manifold/pipe.
NOTE:The heated oxygen sensor MAY be difficult to remove when the engine temperature is less than 48°C (120°F).
NOTE:The heated oxygen sensor in-line connector and louvered end MUST be kept clear of all grease, dirt, and other contaminants. Do NOT use cleaning solvents of any type. Do NOT drop or roughly handle the sensor.
Disconnect and reposition electrical connectors as necessary.
- Using the EN-6179 Heated Oxygen Sensor Remover/Installer, remove the heated oxygen sensor (1).
Turbocharger Heat Shield Bolt (1) - Remove [2x]
Turbocharger Heat Shield Bolt (1) - Remove [2x]
Turbocharger Heat Shield (1) - Remove
Retainer (1) - Unclip
Water Pump Cover Bolt (1) - Remove [3x]
- Water Pump Cover (2) - Remove
Disconnect and reposition electrical connectors as necessary.
- Using the appropriate tool, remove the heated oxygen sensor (1).
Exhaust Pipe Clamp (1) - Loosen
Catalytic Converter Brace Bracket Nut (1) - Remove [2x]
- Catalytic Converter Brace Bolt (2) - Remove [2x]
- Catalytic Converter Brace (3) - Remove
Warm Up Three-Way Catalytic Converter (1) - Remove
- Exhaust Pipe Clamp (2) - Remove and DISCARD
- Catalytic Converter Gasket (3) - Remove and DISCARD
Compressor Air Intake Turbocharger Wastegate Actuator Link Spring (1) - Remove
- Compressor Air Intake Turbocharger Wastegate Actuator Link Clip (2) - Remove
- Compressor Air Intake Turbocharger Wastegate Actuator Rod (3) @ Turbocharger Wastegate Actuator - Disconnect
Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Turbocharger Coolant Feed and Return Pipe (2) @ Exhaust Manifold Outlet Pipe - Remove
Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Turbocharger Coolant Feed Hose (2) @ Turbocharger Coolant Feed and Return Pipe - Remove
Turbocharger Coolant Feed and Return Pipe Bolt (1) - Remove [2x]
Turbocharger Coolant Feed and Return Pipe (1) - Remove
- Turbocharger Coolant Feed and Return Pipe Gasket (2) - Remove and DISCARD
Retainer (1) - Disconnect [3x]
- Electrical Connector (2) - Disconnect [2x]
- Reposition the front axle vent hose (3), and electrical harness (4).
- CAUTION:
The Positive Crankcase Ventilation (PCV) line is tamper resistant and must always be replaced once it is removed. The fittings connected to the PCV line must also be replaced if they are damaged when the PCV line is removed. To reduce the risk of damage to the fittings, use a suitable cutting tool and carefully cut the connections away.
NOTE:Disconnecting the tamper resistant connections will damage the positive crankcase ventilation tube, it must be replaced after removal.
Use a suitable tool to disconnect the 6 locking tabs at each tamper resistant connection.
- Positive Crankcase Ventilation Tube (1) - Remove and DISCARD
Turbocharger Brace Nut (1) - Remove
- Turbocharger Bracket Bolt (2) - Remove [2x]
- Turbocharger Brace (3) - Remove
- Turbocharger Oil Feed Pipe Bolt (4) - Remove [4x]
Turbocharger Nut (1) - Remove and DISCARD [2x]
- Turbocharger Bolt (2) - Remove and DISCARD [2x]
Turbocharger Assembly (1) - Remove
- Turbocharger Gasket (2) - Remove and DISCARD
Turbocharger Oil Feed Pipe Bolt (1) @ Compressor Air Intake Turbocharger - Remove [2x]
- Turbocharger Oil Feed Pipe (2) - Remove
- Turbocharger Oil Return Pipe Gasket (3) - Remove and DISCARD
- Turbocharger Oil Feed Pipe Gasket (4) - Remove and DISCARD
- Turbocharger Oil Return Pipe Gasket (5) - Remove and DISCARD
Turbocharger Stud (1) - Remove and DISCARD [2x]
Front Axle Vent Hose (1) - Remove
Front Wheel Drive Intermediate Shaft Retaining Ring (1) - Remove and DISCARD
- Apply a small amount of lubricant to the front wheel drive intermediate shaft (2) splines. Adhesives, Fluids, Lubricants, and Sealers
- Install the front wheel drive intermediate shaft (2) into the front differential carrier (3).
Front Differential Carrier Bolt (1) - Remove [2x]
- Front Differential Carrier Bolt (2) - Remove
Front Differential Carrier Bolt (1) - Remove
Front Differential Carrier (2) - Remove
Intake Manifold Cover Bolt (1) - Remove [2x]
- Disconnect the electrical connectors.
- Intake Air Pressure and Temperature Sensor (3)
- Throttle Body (4)
Wiring Harness Retainer (2) - Disconnect [2x]
- Reposition the engine wiring harness away from the intake manifold.
Wiring Harness Retainer (1) - Disconnect
Oil Level Indicator (4) - Remove
- Oil Level Indicator Tube Bracket Bolt (1) - Remove
- Oil Level Indicator Tube (2) - Remove
- Oil Level Indicator Tube Seal (3) - Remove and DISCARD
Evaporative Emission Canister Purge Tube (3) - Disconnect - Plastic Collar Quick Connect Fitting Service
Wiring Harness Retainer (1) @ Evaporative Emission Canister Purge Pump Bracket (2) - Unclip
Evaporative Emission Canister Purge Pump Bolt (1) - Remove [3x]
- Evaporative Emission Canister Purge Pump (2) - Remove
Intake Manifold Cover (1) - Remove
Intake Manifold Bolt (1) - Remove [6x]
- Intake Manifold (2) - Remove
Intake Manifold Gasket (3) - Remove and DISCARD [4x]
- Crankcase Vent Passage Seal (4) - Remove and DISCARD
Hose Clamp (1) - Disengage [3x] - Hose Clamp Replacement Guidelines - Spring Type
- Engine Coolant Flow Control Valve Hose (2) @ Engine Coolant Flow Control Valve - Remove
- Engine Oil Cooler Coolant Inlet Hose (3) @ Engine Coolant Flow Control Valve - Remove
- Radiator Inlet Hose (4) @ Engine Coolant Flow Control Valve - Remove
Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Thermostat Bypass Hose (2) @ Engine Coolant Flow Control Valve - Remove
- Disengage the hose clamp (3) and slide it towards the rear of the thermostat bypass hose. Hose Clamp Replacement Guidelines - Spring Type
Electrical Connector (1) @ Engine Coolant Flow Control Valve - Disconnect [2x]
- Engine Coolant Temperature Sensor Electrical Connector (2) @ Engine Coolant Flow Control Valve - Disconnect
Engine Wiring Harness Bracket Nut (1) - Remove [2x]
- Engine Wiring Harness Bracket (2) - Remove
Exhaust Manifold Outlet Pipe Bolt (1) - Remove
Exhaust Manifold Outlet Pipe Bolt (1) - Remove [2x]
- Exhaust Manifold Outlet Pipe (2) - Remove
- Exhaust Manifold Outlet Pipe Gasket (3) - Remove and DISCARD
Engine Coolant Thermostat Housing Bracket Bolt (1) - Remove
Engine Coolant Flow Control Valve Bolt (1) - Remove [5x]
Separate the engine coolant flow control valve (1) from the thermostat bypass hose and remove the engine coolant flow control valve.
- Engine Coolant Flow Control Valve Seal (2) - Remove and DISCARD
Auxiliary Generator Battery Jumper Cable Terminal Nut (1) - Remove
- Auxiliary Generator Battery Jumper Cable (2) - Reposition away
- Retainer (3) - Disengage
Starter Stud (1) - Remove
- Starter Bolt (2) - Remove [2x]
- Reposition the starter to gain access to the electrical connections.
Battery Positive Cable Nut (1) @ Starter Solenoid - Remove
- Auxiliary Generator Battery Jumper Cable (2) - Remove
- Electrical Connector (4) - Disconnect
- Starter (3) - Remove
-
Use a suitable tool to rotate the drive belt tensioner (1) counterclockwise to relieve tension from the drive belt (2).
- Remove the drive belt (2) from the pulleys and tensioner (1).
- Slowly release tension on the drive belt tensioner (1).
- Clean and inspect the drive belt surfaces of all the pulleys.
Drive Belt Idler Pulley (2) - Remove
Drive Belt Tensioner Bolt (3) - Remove [2x]
- Drive Belt Tensioner (4) - Remove
Belt Idler Pulley (1) - Remove
Battery Positive Cable Nut (1) @ Generator - Remove
- Auxiliary Generator Battery Jumper Cable (2) - Remove
- Electrical Connector (5) - Disconnect
- If the generator is being replaced, remove the radiator inlet hose bracket bolt (4) and transfer the radiator inlet hose bracket (3) to the NEW generator.
Generator Bolt (1) - Remove [2x]
Generator (1) - Remove
Air Conditioning Compressor Nut (1) - Remove
Air Conditioning Compressor Nut (1) - Remove
- Air Conditioning Compressor Bolt (2) - Remove
- Remove the air conditioning compressor (3).
Repeat the following steps for all torque converter bolts (1):
- Rotate the harmonic balancer center bolt clockwise ONLY, to align the torque converter bolt with the starter opening.
- Torque Converter Bolt (1) - Remove [6x]
Disconnect the electrical connectors. (1)
- Wiring Harness Retainer (2) - Remove
Wiring Harness Retainer (1) - Remove
Transmission Bolt (1) - Remove [3x]
- Transmission Stud (2) - Remove
Transmission Bolt (2) - Remove [3x]
- Transmission Stud (1) - Remove
Transmission Stud (1) - Remove
- Disconnect the transmission vent hose from the transmission.
- Support the transmission with a suitable jack.
- Pull the transmission straight back.
Install the J-21366 Converter Holding Strap (1) onto the transmission bell housing to retain the torque converter.
Remove the transmission. (1)
EN-36857 Engine Lift Bracket Set (1) - Install
- EN-51768 Engine Support Fixture Adapter Bolts- M8 (2) - Install and tighten 65 N.m (48 lb ft)
EN-36857 Engine Lift Bracket Set (1) - Install
- EN-51768 Engine Support Fixture Adapter Bolts- M8 (2) - Install and tighten 65 N.m (48 lb ft)
Engine Mount Nut- Left Side (1) - Remove
Engine Mount Nut- Right Side (1) - Remove
J-36854 Engine Stand Engine (1) @ - Install
Remove the fuel feed pipe bolt (1).
Disconnect the fuel feed pipe (1) from the fuel pump and the fuel feed pipe - underbody. Metal Collar Quick Connect Fitting Service
Fuel Pump Shield Bolt (1) - Remove [2x]
- Fuel Pump Shield Bolt (2) - Remove [2x]
- Fuel Injection Pump Bracket (3) - Remove
- WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.
Fuel Pump Insulator (1) - Remove
Nut @ Fuel Feed Intermediate Pipe (1) - Loosen [2x]
Fuel Injection Fuel Feed Pipe Bracket Bolt (1) - Remove
- Fuel Feed Intermediate Pipe (2) - Remove and DISCARD
- Electrical Connector @ Fuel Pump - Disconnect
- CAUTION:
Alternately loosen the fuel pump bolts one turn at a time until the pump is fully disengaged from fuel pump lifter follower. Trying to remove the pump bolts without even side-to-side loosening may result in pump plunger damage
Fuel Pump Stud (1) - Remove [2x]
- Fuel Pump (2) - Remove
- Fuel Pump Seal (3) - Remove and DISCARD
- Valve Lifter Follower (4) - Remove
Engine Wiring Harness Bracket Nut (1) - Remove [2x]
- Engine Wiring Harness Bracket (2) - Remove
Ignition Coil Bolt (1) - Remove [8x]
- Ignition Coil (2) - Remove [4x]
Engine Mount Bracket Bolt (1) - Remove and DISCARD [4x]
- Engine Mount Bracket (2) - Remove
- WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.
Fuel Injection Fuel Rail Noise Shield (1) - Remove
Electrical Connector (1) - Disconnect
- Fuel Injection Fuel Rail Bolt (2) - Remove [4x]
- NOTE:
Use care to avoid contact with the fuel rail harness during special tool installation and fuel rail removal.
Install the EN-49248 Injector Rail Assembly Remover.
- Electrical Connector (1) @ Knock Sensor - Disconnect [2x]
- Turn BOTH handles simultaneously, in small, even increments
- DO NOT twist the fuel injector fuel rail while removing.
- Turn both handles on the EN-49248 Injector Rail Assembly Remover to disengage the fuel injection fuel rail.
- Remove the EN-49248 Injector Rail Assembly Remover.
- Direct Fuel Injection Fuel Rail - Remove
Water Outlet Bolt (1) - Remove [3x]
- Loosen the hose clamp to be able to remove from water pump.
- Water Inlet (2) - Remove
- Water Pump Inlet Gasket (3) - Remove and DISCARD
Heater Outlet Pipe Bolt (1) - Remove
Water Pump Bolt (1) - Remove [3x]
- CAUTION:
Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method.
Fuel Injector Retainer (1) - Remove and DISCARD [4x]
- Direct Fuel Injector (2) - Remove [4x]
- CAUTION:
Do not use a metal tool to remove O-rings, spacers or injector seals. Care must be taken not to scratch or damage the tubes of the injector.
Fuel Injector Bushing (4) - Remove and DISCARD [4x]
- Fuel Injector Seal (1) - Remove and DISCARD [4x]
- Fuel Injector Seal Spacer (2) - Remove and DISCARD [4x]
- Fuel Injector Nozzle Housing Seal (3) - Remove and DISCARD [8x]
Cap the fittings and plug the holes when removing the transmission fluid cooler pipes.
Cap the fittings and plug the holes when removing the transmission fluid cooler pipes.
Cap the fittings and plug the holes when removing the transmission fluid cooler pipes.
Provide additional support when a vehicle is on a hoist in the following ways:
Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.
When removing the propeller shaft, do not remove the propeller shaft coupler from the propeller shaft assembly. The only bolts that should be removed are those that mount each coupler to the transmission output flange, and to the rear drive axle input flange. Failure to properly remove the propeller shaft assembly may cause coupler damage, resulting in necessary replacement of the entire propeller shaft.
Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.
Provide additional support when a vehicle is on a hoist in the following ways:
Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.
Electrostatic discharge (ESD) can damage many solid-state electrical components. ESD susceptible components may or may not be labeled with the ESD symbol. Handle all electrical components carefully. Use the following precautions in order to avoid ESD damage:
During removal and installation, all EPS components including mechanical and/or electrical is extremely susceptible to damage. Dropping or prying on any EPS component may cause internal damage. If damage occurs or a part is dropped, the EPS component must be replaced.
Care must be taken during removal and installation of the Electronic Power Steering (EPS) components to not hit or break the EPS motor/controller module or module harness connectors. If the EPS motor/ controller module or module connectors are damaged, the complete component must be replaced.
With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components:
After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has become un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil.
Vehicle alignment is not required if the cradle is being lowered or dropped to perform another procedure. This vehicle is equipped with a cradle to body aligning feature: cradle to body through holes or self-aligning pins that are part of the cradle or body. Only align if replacing the cradle with a NEW part and transferring components.
Insert suitable flat edge tool into gaps between bracket and mounting surface and apply alternate and even pressure to gently rock bracket out of mating recess.
The front wheel drive intermediate shaft bracket bearing is not serviced separately. If the bearing is worn or damaged, replace the front wheel drive intermediate shaft bracket assembly.
DT-51504 must be installed into the differential output shaft seal prior to removing and installing the wheel drive shaft. Failure to install the DT-51504 as indicated may cause the splines of the wheel drive shaft to damage the differential output seal
The heated oxygen sensor MAY be difficult to remove when the engine temperature is less than 48°C (120°F).
The heated oxygen sensor in-line connector and louvered end MUST be kept clear of all grease, dirt, and other contaminants. Do NOT use cleaning solvents of any type. Do NOT drop or roughly handle the sensor.
When removing, handling or installing this component wear protective gloves. The sharp edges on the component may be very sharp and may cause injury.
Refer to Fastener Caution .