Removal Procedure
- Remove the negative battery cable from the battery. Battery Negative Cable Disconnection and Connection (9C1, 5W4) , or Battery Negative Cable Disconnection and Connection (KL9)
- Remove the oil level indicator. (1)
- Air Cleaner Outlet Duct Bracket Bolt (1) - Remove
- Remove engine wiring harness from air cleaner outlet duct bracket.
- Positive Crankcase Ventilation Fresh Air Tube (1) - Disconnect - Plastic Collar Quick Connect Fitting Service
- Air Cleaner Outlet Duct Clamp (2) - Loosen [2x]
- Air Cleaner Outlet Duct (3) - Remove
- Using a suitable tool, cut the accessory drive primary belt (1).NOTE:
The accessory drive primary belt is not reusable.
- Accessory Drive Primary Belt (1) - Remove and DISCARD
- Using a suitable tool, cut the accessory drive auxiliary belt (1).NOTE:
The accessory drive auxiliary belt is not reusable.
- Accessory Drive Auxiliary Belt (1) - Remove and DISCARD
- Battery Positive Cable Nut (1) - Remove
- Starter Solenoid Cable (2) - Remove
- Electrical Connector (3) - Disconnect
- Retaining Tab (1) - Disengage [2x]
- Engine Wiring Harness Junction Block Cover (2) - Remove
- Battery Positive Cable Nut (3) - Remove
- Starter Solenoid Cable (4) - Remove
- Engine Wiring Harness Junction Block Bolt (2) - Loosen [4x]
- Retaining Tab (1) - Disengage [4x]
- Engine Wiring Harness Junction Block (3) - Remove
- Electrical Connector (1) - Remove [4x]
- Engine Wiring Harness Fuse Block Bracket Bolt (2) - Remove [2x]
- Retaining Tab (1) - Disengage
- Engine Wiring Harness Fuse Block Bracket (3) - Remove
- Oil Level Indicator Tube Bolt (1) - Remove
- Remove both front tire and wheel assemblies. Tire and Wheel Removal and Installation (Steel Wheel) , or Tire and Wheel Removal and Installation (Aluminum Wheel)
- Drain the cooling system. Cooling System Draining and Filling (GE 47716 L84, L87) , or Cooling System Draining and Filling (Static L84, L87)
- Engine Oil and Oil Filter - Remove and DISCARD - Engine Oil and Oil Filter Replacement
- Front Bumper Fascia Skid Plate Bolt (1) - Remove [4x]
- Underbody Splash Shield Bolt (2) - Remove [4x]
- Underbody Splash Shield (1) - Remove
- Underbody Splash Shield Bolt (2) - Remove [2x]
- Underbody Skid Shield (3) - Remove
- Engine Oil Cooler Hose Clip (1) - Release
- Have an assistant apply the brakes.
- Front Wheel Drive Shaft Nut (1) - Remove and DISCARDCAUTION:
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 DISCARDCAUTION:
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.
- Install the DT-45859
Axle Remover (2) to the front wheel hub and secure with 2 wheel nuts (1) hand tightened.
- Using the DT-45859 Axle Remover (2), release the front wheel drive half shaft from the front wheel hub.
- Remove the 2 wheel nuts (1) and the DT-45859 Axle Remover (2) from the front wheel hub.
- Front Brake Hose Bracket Bolt (1) - Remove
- Front Brake Caliper Bolt (2) - Remove [2x]
- Remove the brake caliper and support with heavy mechanics wire. (1)
- Front Wheel Speed Sensor Bolt (1) - Remove
- Front Wheel Speed Sensor (2) - Remove
- Front Wheel Speed Sensor Bracket Bolt (3) - Remove
- Front Wheel Speed Sensor Bracket (4) - Remove
- Front Wheel Speed Sensor Bracket Bolt (1) - Remove
- Remove the front wheel speed sensor wiring harness bracket (2).
- Steering Linkage Outer Tie Rod Nut (1) - Remove
- Using the CH-43631
Ball Joint Separator (1), remove the steering linkage outer tie rod from the steering knuckle.CAUTION:
Do not attempt to disconnect a steering linkage joint by driving a wedge between the joint and the attached part. Seal damage may result which will cause premature failure of the joint.
- Front Stabilizer Shaft Link Nut (1) - Remove
- Front Stabilizer Shaft Link@Lower Control Arm - Remove
- Support the lower control arm with a suitable jack stand.
- Front Upper Control Arm Ball Stud Nut (1) - Loosen
- Using the CH-42188-B
Ball Joint Separator (1), separate the right front upper control arm (2) from the steering knuckle.
- Remove the CH-42188-B Ball Joint Separator (1) from the right front upper control arm (2) and the steering knuckle.
- Front Upper Control Arm Ball Stud Nut (1) - Remove
- Remove jack stand.
- Using a suitable flat bladed tool (1), release the front wheel drive half shaft (2) from the front differential carrier.CAUTION:
Wheel drive shaft boots, seals and clamps should be protected from sharp objects any time service is performed on or near the wheel drive shaft(s). Damage to the boot(s), the seal(s) or the clamp(s) may cause lubricant to leak from the joint and lead to increased noise and possible failure of the wheel drive shaft.
NOTE:Some components not shown for graphic clarity.
- Remove the front wheel drive half shaft (1) from the front axle.NOTE:
Some components not shown for graphic clarity.
- Remove the front wheel drive half shaft (1) from the wheel hub.
- Front Wheel Drive Shaft Retaining Ring (1) - Remove and DISCARD
- Front Wheel Drive Shaft Seal (2) - Remove and DISCARD
- Install the DT-45859
Axle Remover (2) to the front wheel hub and secure with 2 wheel nuts (1) hand tightened.
- Using the DT-45859 Axle Remover (2), release the front wheel drive half shaft from the front wheel hub.
- Remove the 2 wheel nuts (1) and the DT-45859 Axle Remover (2) from the front wheel hub.
- Front Brake Hose Bracket Bolt (1) - Remove
- Front Disc Brake Pad Wear Sensor (1) @Front Brake Caliper - RemoveNOTE:
Only the left front wheel is equipped with the front disc brake pad wear sensor.
- Front Brake Caliper Bolt (2) - Remove [2x]
- Remove the brake caliper and support with heavy mechanics wire. (1)
- Front Wheel Speed Sensor Bolt (1) - Remove
- Front Wheel Speed Sensor (2) - Remove
- Front Wheel Speed Sensor Bracket Bolt (3) - Remove
- Front Wheel Speed Sensor Bracket (4) - Remove
- Front Wheel Speed Sensor Bracket Bolt (1) - Remove
- Remove the front wheel speed sensor wiring harness bracket (2).
- Steering Linkage Outer Tie Rod Nut (1) - Remove
- Using the CH-43631
Ball Joint Separator (1), remove the steering linkage outer tie rod from the steering knuckle.CAUTION:
Do not attempt to disconnect a steering linkage joint by driving a wedge between the joint and the attached part. Seal damage may result which will cause premature failure of the joint.
- Front Stabilizer Shaft Link Nut (1) - Remove
- Front Stabilizer Shaft Link@Lower Control Arm - Remove
- Support the lower control arm with a suitable jack stand.
- Front Upper Control Arm Ball Stud Nut (1) - Loosen
- Using the CH-42188-B
Ball Joint Separator (1), separate the left front upper control arm (2) from the steering knuckle.
- Remove the CH-42188-B Ball Joint Separator (1) from the left front upper control arm (2) and the steering knuckle.
- Front Upper Control Arm Ball Stud Nut (1) - Remove
- Remove jack stand.
- Using a suitable flat bladed tool (1), release the front wheel drive half shaft (2) from the front differential carrier.CAUTION:
Wheel drive shaft boots, seals and clamps should be protected from sharp objects any time service is performed on or near the wheel drive shaft(s). Damage to the boot(s), the seal(s) or the clamp(s) may cause lubricant to leak from the joint and lead to increased noise and possible failure of the wheel drive shaft.
NOTE:Some components not shown for graphic clarity.
- Remove the front wheel drive half shaft (1) from the front axle.NOTE:
Some components not shown for graphic clarity.
- Remove the front wheel drive half shaft (1) from the wheel hub.
- Front Wheel Drive Shaft Retaining Ring (1) - Remove and DISCARD
- Front Wheel Drive Shaft Seal (2) - Remove and DISCARD
- Front Wheelhouse Liner- Left Side - Remove - Front Wheelhouse Liner Replacement
- Unclip and reposition the chassis wiring harness bracket (1) away from the frame shock tower.
- Front Shock Absorber Nut (1) - Remove [3x]
- Front Shock Absorber Bolt (1) - Remove [2x]
- Front Shock Absorber (1) - Remove
- Front Stabilizer Shaft Bolt (1) - Remove [4x]NOTE:
Support the front stabilizer shaft.
- Front Stabilizer Shaft Clamp (2) - Remove [2x]
- Front Stabilizer Shaft (3) - Remove
- Mark a reference point between the front axle propeller shaft (1) and the front differential drive pinion gear yoke.
- Front Axle Propeller Shaft Bolt (2) - Remove [6x]
- Front Axle Propeller Shaft Washer (3) - Remove [3x]
- Front Axle Propeller Shaft (1) - Reposition away
- Disconnect the front drive axle actuator electrical connector (1).
- Release the two harness retainers (2) and reposition harness.
- Electrical Connector@Heater Coolant Pump (2) - DisconnectNOTE:
Some components not shown for graphic clarity.
- Heater Water Auxiliary Pump Bolt (1) - Remove
- Remove the heater coolant pump and heater water auxiliary pump bracket (2) as assembly and position aside.
- Support the front axle with a hydraulic jack.
- Front Differential Carrier Nut (1) - Remove
- Front Differential Carrier Bolt (2) - Remove and DISCARD
- Drivetrain and Front Suspension Frame Reinforcement Nut (1) - Remove [4x]
- Drivetrain and Front Suspension Frame Reinforcement Bolt (2) - Remove [4x]
- Drivetrain and Front Suspension Frame Front Crossmember (1) - Remove
- Front Differential Carrier Bracket Nut (1) - Remove
- Front Differential Carrier Bolt (2) - Remove
- Front Differential Carrier Bolt (1) - Remove
- Front Axle Vent Hose - Disconnect
- Front Axle (1) - Remove
- Torque Converter Cover Bolt-Left Side (1) - Remove
- Transmission Converter Cover-Left Side (2) - Remove
- Engine Oil Cooler Hose Bracket Nut (1) - Remove
- Engine Oil Pressure Sensor Sleeve (1) - Remove
- Electrical Connector (1) @Engine Oil Pressure Sensor - Disconnect
- Wiring Harness Retainer (2) @Engine Oil Cooler Hose - Remove
- Engine Oil Cooler Adapter Bolt (1) - Remove [2x]
- Engine Oil Cooler Hose (1) @Oil Pan - Reposition
- Engine Oil Cooler Gasket (2) - Remove and DISCARD
- Electrical Connector@Knock Sensor (4) - Disconnect
- Remove the transmission fluid auxiliary cooler pipe bracket nut (1) from the oil pan.
- Engine Wiring Harness Retainer (2) - Remove
- Engine Wiring Harness Ground Stud (1) - Remove [2x]
- Engine Wiring Harness (3) @Oil Pan - Reposition
- Engine Wiring Harness Retainer (1) @Oil Level Indicator Tube (2) - Disconnect
- Disconnect the wiring harness connectors and retainers as necessary.
- Transmission Fluid Cooler Pipe Clip Bolt (1) @Oil Pan - Remove
- Transmission Fluid Cooler Pipe Clip Bracket (2) @Oil Pan - Remove
- Reposition the transmission cooler inlet and outlet pipe (1) as necessary.
- Oil Level Indicator Tube (1) @Oil Pan - Remove
- Oil Level Indicator Seal (2) - Remove and DISCARD
- Oil Level Indicator Tube (1) - Reposition
- Starter Heat Shield Bolt (1) - Remove [2x]
- Starter Heat Shield Bolt (1) - Remove
- Starter Heat Shield (2) - Remove
- Battery Negative Cable Ground Bolt (1) - Remove
- Starter Solenoid Cable (2) - Reposition away
- Starter Bolt (1) - Remove [2x]
- Reposition the starter (2) to access the electrical connections.
- Protective Sleeve (4) - Reposition
- Starter Solenoid Cable Nut (2) - Remove
- Starter Solenoid Cable (1) - Remove
- Electrical Connector (3) - Disconnect
- Starter (1) - Remove
- Torque Converter Cover Bolt- Right Side (1) - Remove
- Transmission Converter Cover- Right Side (2) - Remove
- Position the EN-42386
Flywheel Holding Tool (1) into place.
- Install the M10-1.5 x 120mm (3) and the M10-1.5 x 45mm (2) bolts and tighten to 50 N.m (37 lb ft).
- Transmission Bolt (1) - Remove [2x]
- Electrical Connector (1) - Disconnect
- Oil Pan Bolt (2, 3) - Remove [16x]
- Oil Pan (1) - Remove
- Oil Pan High Pressure Port Seal (2) - Remove and DISCARD [2x]
- Oil Pan Front Seal (3) - Remove and DISCARD
- Air Conditioning Compressor Bolt (1) - RemoveNOTE:
It is not necessary to recover and recharge the refrigerant to perform this repair.
- Air Conditioning Compressor Nut (2) - Remove
- Air Conditioning Compressor Stud (3) - Remove
- Air Conditioning Compressor (1) - Position aside
- Crankshaft Balancer Bolt (1) - Remove and DISCARD
- Install the EN-41816-A
Crankshaft Balancer Remover (1) and the EN-44226-5
Crankshaft Protector (3) crankshaft balancer (2).
- Using the EN-41816-A
Crankshaft Balancer Remover (1) and the EN-44226-5
Crankshaft Protector (2) remove the crankshaft balancer (3) from the crankshaft.
- Remove the EN-41816-A Crankshaft Balancer Remover (1) and the EN-44226-5 Crankshaft Protector (2) from the crankshaft balancer (3).
- Radiator Surge Tank Outlet Hose Clip (2) - Remove [2x]
- Radiator Surge Tank Outlet Hose (3) - Position aside
- Radiator Inlet Hose Clip (2) - Remove
- Radiator Inlet Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Inlet Hose (3) @Engine Radiator - Remove and position aside
- Wiring Harness Retainer (1) - Remove [2x]
- Electrical Connector (3) - Disconnect
- Wiring Harness (2) - Position aside
- Wiring Harness Retainer (2) - Remove [2x]
- Electrical Connector (1) - Disconnect
- Wiring Harness (3) - Position aside
- Engine Oil Cooler Retainer (2) - Remove [2x]
- Engine Oil Cooler Pipe Bracket Bolt (3) - Remove
- Engine Oil Cooler Hose (1) @Engine Radiator - Remove [2x]
- Transmission Fluid Cooler Pipe Bolt (1) - Remove
- Transmission Fluid Cooler Pipe Clip (2) - Remove [2x]
- Transmission Fluid Cooler Pipe Clip (1) - Release
- Engine Coolant Fan Bracket Bolt (1) - Remove [2x]
- Engine Cooler Fan (1) @Engine Radiator - Remove
- Generator Bolt (1) - Remove [2x]
Generator (1) - Remove - Hose Clamp (1) - Disengage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Heater Inlet Hose (2) @Water Pump - Remove
- Heater Water Auxiliary Pump Hose (3) @Water Pump - Remove
- Radiator Outlet Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Outlet Hose (2) @Water Pump - Remove
- Hose Clamp (1) - Disengage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Engine Coolant Air Bleed Hose (2) @Water Pump - Remove
- Radiator Inlet Hose (3) @Water Pump - Remove
- Engine Coolant Temperature Sensor Electrical Connector (1) - Disconnect
- Water Pump Housing Bolt (1) - Remove [6x]
- Water Pump (1) - Remove
- Water Pump Gasket (2) - Remove and DISCARD [2x]
- If the engine front cover is reused perform the following steps:
- Install the EN-51096
Seal Remover (2) to the GE-23907-1
Slide Hammer with Shaft (1).
- Slide the large bend of the EN-51096 Seal Remover (2) between the lip of the crankshaft front oil seal and crankshaft. Ensure that the larger bend of the EN-51096 Crankshaft Seal Remover (2) engages the rear side of the crankshaft front oil seal (3).
- Using the EN-51096 Seal Remover (2) and the GE-23907-1 Slide Hammer with Shaft (1) remove the crankshaft front oil seal (3).
- Crankshaft Front Oil Seal (1) - Remove and DISCARD
NOTE:EN-51096 Crankshaft Seal Remover (2) has two ends. The end with the larger bend will be used to remove the crankshaft front oil seal (3).
- Install the EN-51096
Seal Remover (2) to the GE-23907-1
Slide Hammer with Shaft (1).
- Engine Front Cover Bolt (1, 3) - Remove [10x]
- Engine Front Cover (2) - Remove
- Oil Pump Bolt (1) - Remove [4x]
- Oil Pump (1) - Remove
- Compress the tensioner blade and install the EN-46330
Timing Belt Tensioner Retaining Pin (1) into the timing chain tensioner (2).
- Camshaft Position Actuator Solenoid Valve (1) - Remove and DISCARD
- Loosen and separate the camshaft position actuator (3) and timing chain (1) from the camshaft as an assembly. Position fingers behind the actuator sprocket (2) and pull the actuator (3) and sprocket (2) away from the front of the camshaft. Never pull on the reluctor wheel (3) when attempting to remove the actuator.WARNING:
Refer to Camshaft Position Actuator Removal and Installation Warning .
- Remove the camshaft position actuator sprocket (2) and timing chain (1) as an assembly.
- Insert a tie strap through the center of the actuator (3) and over the reluctor wheel to hold it together.
- Timing Chain Tensioner Bolt (1) - Remove [2x]
- Timing Chain Tensioner (2) - Remove
- Crankshaft Sprocket (1) @Crankshaft - Remove
- Using the appropriate tool, clean and prepare the applicable sealing surface.
CAUTION:
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.
NOTE:
Support the lower control arm to prevent over-articulation of the front lower control arm ball joint.
CAUTION:
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.
NOTE:
Support the lower control arm to prevent over-articulation of the front lower control arm ball joint.
NOTE:
Ensure that the front axle is securely attached to the hydraulic jack.
NOTE:
The front axle may have to be maneuvered to remove it from the vehicle.
NOTE:
Components removed in graphic to better illustrate service parts.
NOTE:
If the engine front cover is reused, the crankshaft front oil seal must be replaced.