Removal Procedure
- Recover the refrigerant. Refrigerant Recovery and Recharging
- Remove the radiator surge tank cap.
- Remove charge air cooler coolant filler cap.
- Front Wheelhouse Liner- Left Side and Right Side - Remove [2x] - Front Wheelhouse Liner Replacement
- Attach a rubber hose to the radiator drain port to guide the coolant into the drain pan.
- Place a drain pan under the vehicle.
- Rotate the radiator drain cock counterclockwise to open.
- Drain the cooling system.
- Rotate the radiator drain cock clockwise to close.
- Disconnect the rubber hose.
- Inspect the coolant.
- If the coolant is discolored, perform the flushing procedure. Flushing
- NOTE:
Quantity of fasteners may vary based on option content.
Front Bumper Fascia Air Deflector Bolt (1) - Remove [10x]
- Front Bumper Fascia Extension Bolt (2) - Remove [8x]
Pull the front bumper fascia extension (1) rearward and down from the front bumper fascia.
- NOTE:
The proper position of the underbody skid shield is between the front bumper fascia extension and the front frame.
Underbody Skid Shield Bolt (1) - Remove [4x]
- Underbody Skid Shield (2) - Remove
Front Bumper Fascia Extension Bolt (2) - Remove [4x]
- Remove the front bumper fascia extension (4).
- Drain the engine oil. Engine Oil and Oil Filter Replacement
Plenum Front Panel Outer Reinforcement (1) - Remove - Plenum Front Panel Outer Reinforcement Removal and Installation
- Oil Filler Cap - Remove
Intake Manifold Cover Bolt (1) - Remove
- Intake Manifold Cover (2) - Remove
- Oil Filler Cap - Install
Hood Latch Actuator Bolt (1) - Remove [2x]
- Hood Secondary Latch Release Handle (2) - Remove
Intake Air Baffle Retainer (1) - Remove [9x]
- Intake Air Splash Shield (2) - Remove
- NOTE:
Left side shown, right side similar.
Loosen the 2 left and right side front bumper fascia guide bolts (1).
- Remove the left and right side front bumper fascia bolts (2).
- NOTE:
Left side shown, right side similar.
Remove the left and right side front bumper fascia support brace bolts (1).
Front Grille Bolt (1) - Remove [6x]
Apply a double layer of masking tape to the left and right headlamp to prevent damaging the headlamp lens.
- On the left and right side of the front bumper fascia (1), carefully push a small nylon wedge between the front bumper fascia and the front bumper fascia guide. Insert a suitable flat-bladed plastic trim tool, into the fascia slot and depress the snaps one at a time and pull on the fascia at the same time to gradually remove front bumper fascia.
- Starting at the outside of the headlamp, release the front bumper fascia (1) from the headlamps.
Disconnect the electrical connector.
- Release the 9 grille clips (1).
- With the aid of an assistant, remove the fascia. (2)
- NOTE:
Left side shown, right side similar.
Headlamp Bolt- Left Side and Right Side (1) - Remove [6x]
- NOTE:
Left side shown, right side similar.
Headlamp Bolt- Left Side and Right Side (1) - Remove [6x]
- NOTE:
Left side shown, right side similar.
Release the front headlamp guide pin from the front bumper fascia guide (1).
- Front Headlamp- Left Side and Right Side (2) - Remove [2x]
- Release the wiring harness retaining tab.
- Disconnect all electrical connectors.
- NOTE:
Left side shown, right side similar.
Remove the left and right side front bumper fascia upper stiffener nuts (1).
- Loosen the left and right side front bumper fascia upper stiffener bolts (2).
Pull the front bumper fascia upper stiffener (1) up and out over the studs.
Front Bumper Shutter Bolt (1) - Remove [9x]
- Disconnect the electrical connector.
- Front Bumper Shutter (2) - Remove
- NOTE:
Left side shown, right side similar.
Remove the 2 left and 2 right side front end sheet metal diagonal brace bolts (1).
- Remove the left and right side front end sheet metal diagonal braces (2).
Intake Air Duct Retainer (1) - Remove
- Intake Air Duct (2) - Remove
- NOTE:
Right side shown, left side similar.
Remove the 2 left and 2 right side front end sheet metal diagonal brace bolts (1).
- Remove the left and right side front end sheet metal diagonal braces (2).
Front Grille Support Bracket Bolt (1) - Remove [4x]
- Front Grille Support Reinforcement (2) - Remove
- NOTE:
Left side shown, right side similar.
Front End Upper Tie Bar Bolt- Left Side and Right Side (1) @Headlamp Bracket - Remove [8x]
- Headlamp Bracket- Left Side and Right Side (2) - Remove [2x]
Electrical Connector (1) @Horn (2) - Disconnect
Disconnect the hood release cable (3).
- Disconnect and unclip the electrical connector.
Remove the retainer (2) and reposition the hood primary latch release cable (1) from the upper tie bar.
Front End Upper Tie Bar Bolt (1) - Remove [3x]
Front End Upper Tie Bar Bolt (1) - Remove
Front End Upper Tie Bar Bolt (1) - Remove [3x]
Front End Upper Tie Bar Bolt (1) - Remove
- Disconnect the wiring harness retainers and reposition the harness as necessary.
Front End Upper Tie Bar (1) - Remove
Release the radiator air front lower baffle (1) retainers at the engine auxiliary radiator and reposition away.
Radiator Air Side Baffle Retainer (2) - Remove [4x]
- Radiator Air Side Baffle (1) - Reposition
Radiator Air Side Baffle Retainer (2) - Remove
- Radiator Air Side Baffle (1) - Reposition
Auxiliary Radiator Inlet Hose Clamp (1) @Engine Auxiliary Radiator - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Auxiliary Radiator Inlet Hose (2) @Engine Auxiliary Radiator - Remove
- Drain the charge air cooling system.
- Remove the drain pan.
- Inspect the coolant.
- If the coolant is discolored, perform the flushing procedure. Flushing
Charge Air Cooler Coolant Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Remove the charge air cooler coolant hose (2) from the engine auxiliary radiator and reposition away through the radiator air side baffle.
Transmission Fluid Cooler Pipe Nut (1) - Remove
- Transmission Fluid Cooler Inlet and Outlet Pipe (2) @Transmission Fluid Auxiliary Cooler- Right Side - Remove
- Transmission Fluid Cooler Seal (3) - Remove and DISCARD
- NOTE:
Some components not shown for graphic clarity.
Transmission Fluid Cooler Pipe Nut (1) - Remove
- Transmission Fluid Cooler Inlet and Outlet Pipe (2) @Transmission Fluid Auxiliary Cooler- Left Side - Remove
- Transmission Fluid Cooler Seal (3) - Remove and DISCARD
- Cap the fittings and plug the holes when removing the transmission fluid cooler pipes.
Air Conditioning Condenser and Evaporator Hose Nut (1) - Remove
- NOTE:
Some components not shown for graphic clarity.
Air Conditioning Condenser and Evaporator Hose (2) - Remove
- Air Conditioning Compressor and Condenser Hose Seal (1) - Remove and DISCARD
- NOTE:
Some components not shown for graphic clarity.
Air Conditioning Compressor and Condenser Hose Nut (1) - Remove
- Air Conditioning Compressor and Condenser Hose (2) - Remove
- Air Conditioning Compressor and Condenser Hose Seal (3) - Remove and DISCARD
Charge Air Cooler Coolant Reservoir Bolt (1) - Remove
- Charge Air Cooler Surge Tank (2) - Reposition away
Radiator Outlet Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Outlet Hose (2) @Engine Radiator - Remove
Engine Wiring Harness Fuse Block Bracket Bolt (1) - Remove
- Accessory Wiring Junction Block (2) - Reposition
Radiator Surge Tank Inlet Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Surge Tank Inlet Hose (2) @Engine Radiator - Remove
- Radiator Inlet Hose Clamp (4) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Inlet Hose (3) @Engine Radiator - Remove
Wiring Harness Retainer (1) @Engine Cooler Fan - Remove
- Electrical Connector (2) @Engine Coolant Temperature Sensor - Disconnect
- Electrical Connector (3) @Engine Cooler Fan - Disconnect [2x]
- Transmission Fluid Cooler Pipe Clip (4) @Engine Cooler Fan - Remove
- NOTE:
Some components not shown for graphic clarity.
Electrical Connector (2) @Engine Cooler Fan - Disconnect
- Wiring Harness Retainer (3) @Engine Cooler Fan - Remove
Transmission Fluid Cooler Pipe Clip (1) @Engine Cooler Fan - Remove [2x]
Air Conditioning Compressor and Condenser Hose Retainer (1) @Engine Cooler Fan - Remove [2x]
- Air Conditioning Compressor and Condenser Hose Clip (2) @Engine Cooler Fan - Remove [2x]
Radiator Air Upper Baffle (1) - Remove
- Disconnect the wiring harness retainers and reposition the harness as necessary.
With the aid of an assistant, remove the charge air cooler, condenser, fan, and radiator assembly (1) from the vehicle.
Air Cleaner Outlet Duct Clamp (1) - Loosen [2x]
- Air Cleaner Outlet Front Duct (2) - Remove
- Disconnect the mass airflow sensor electrical connector.
Air Cleaner Housing Cover Bolt (1) - Remove [3x]
- Air Cleaner Upper Housing (2) - Remove
Electrical Connector (1) @Air Cleaner Lower Housing - Remove
Air Cleaner Nut (1) - Remove
- Remove all retainers from air cleaner lower housing.
Air Cleaner Lower Housing (1) - Remove
Air Cleaner Outlet Duct Clamp (1) - Loosen
- Air Cleaner Outlet Duct (2) - Remove
Charge Air Cooler Inlet Air Hose Clamp (1) - Loosen until disengaged [2x]
- Charge Air Cooler Inlet Air Hose (2) - Remove
Charge Air Cooler Outlet Air Hose Clamp (1) - Loosen until disengaged [2x]
- Charge Air Cooler Outlet Air Hose (2) - Remove
Release the retaining spring (1).
- Intake Manifold Resonator (2) - Remove
Electrical Connector (1) @Charge Air Cooler - Disconnect [2x]
- Wiring Harness Retainer (2) @Charge Air Cooler - Remove [3x]
Hose Clamp (1) - Disengage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Charge Air Cooler Coolant Hose (2) @Charge Air Cooler - Remove
- Charge Air Cooler Coolant Hose (3) @Charge Air Cooler - Remove
- Wiring Harness Retainer (4) @Charge Air Cooler - Remove
Nitrogen Oxides Sensor Nut (1) - Remove [2x]
- Disconnect the nitrogen oxides sensor electrical connector.
- Nitrogen Oxides Sensor- Position 1 (2) - Remove
- NOTE:
Some components not shown for graphic clarity.
Upper Intake Manifold Brace Nut (1) - Remove [3x]
- Upper Intake Manifold Bracket (2) - Remove
Charge Air Cooler Bolt (1) - Remove [4x]
Charge Air Cooler - (1) Remove
Engine Wiring Harness Bracket Nut (1) - Remove [3x]
- Position the rear engine wiring harness channel (2).
Engine Coolant Outlet Pipe Bracket Bolt (1) - Remove
Engine Coolant Air Bleed Hose Clip (1) - Remove
Engine Coolant Air Bleed Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Engine Coolant Air Bleed Hose (2) - Position aside
- NOTE:
Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.
Exhaust Gas Recirculation Cooler Bolt (2) - Remove [2x]
Turbocharger Coolant Return Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Turbocharger Coolant Return Hose (2) @Turbocharger Coolant Feed Pipe - Remove and position aside
- Turbocharger Coolant Feed Pipe Bolt (3) - Remove
Remove the turbocharger coolant return hose clip (1) and position the turbocharger coolant return hose out of the way.
- Exhaust Gas Recirculation Outlet Pipe Bolt (2) - Remove
Exhaust Gas Recirculation Outlet Pipe Bolt (1) - Remove [2x]
Exhaust Gas Recirculation Pipe (1) - Remove
- Exhaust Gas Recirculation Pipe Seal (2) - Remove and DISCARD
- Exhaust Gas Recirculation Cooler Inlet Pipe Gasket (3) - Remove and DISCARD
Exhaust Gas Recirculation Cooler Temperature Sensor (2) - Remove and position aside
Turbocharger Heat Shield Bolt (1) - Remove [2x]
- Turbocharger Heat Shield Nut (2) - Remove
Turbocharger Heat Shield (1) - Remove
Turbocharger Bracket Bolt (1) - Remove
Remove the engine wiring bracket retainer (1).
Engine Wiring Harness Bracket Nut (1) - Remove [2x]
- Engine Wiring Harness Bracket Bolt (2) - Remove
- Engine Wiring Harness Bracket (3) - Reposition
Disconnect the electrical connector. (3)
Oil Filler Tube Support Stud (2) - Remove
- Oil Filler Tube (3) - Remove
Charge Air Cooler Bolt (1) - Remove [5x]
- Charge Air Cooler Bracket (2) - Remove
Battery Hold Down Strap Bolt (1) - Remove [2x]
- Battery Hold Down Strap (2) - Remove
Retaining Tab (1) - Disengage [2x]
- Front Compartment Fuse Block Cover (2) - Remove
Battery Positive Post Clamp Nut (1) - Loosen
Electrical Connector (1) - Disconnect
Retaining Tab (1) - Disengage [3x]
- Battery Distribution Engine Compartment Fuse Block (2) - Reposition
Battery Hold Down Retainer Bolt (1) - Remove
- Battery Hold Down Retainer (2) - Remove
Battery (1) - Remove
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
Air Conditioning Compressor and Condenser Hose Nut (2) @Air Conditioning Refrigerant Heat Exchanger - Remove
- Air Conditioning Compressor and Condenser Hose (3) @Air Conditioning Refrigerant Heat Exchanger - Remove
- Air Conditioning Compressor and Condenser Hose Seal- Large (4) - Remove and DISCARD
- Air Conditioning Condenser and Evaporator Hose Clip (6) - Remove
- Air Conditioning Condenser and Evaporator Hose (1) - Remove
- Air Conditioning Compressor and Condenser Hose Seal- Small (5) - Remove and DISCARD
Air Conditioning Refrigerant Heat Exchanger Nut (1) @Battery Tray - Remove
Air Conditioning Evaporator Thermal Expansion Valve Hose Nut (1) - Remove
- Air Conditioning Refrigerant Heat Exchanger (2) - Reposition
- Air Conditioning Evaporator Thermal Expansion Valve Seal- Large (3) - Remove and DISCARD
- Air Conditioning Evaporator Thermal Expansion Valve Seal- Small (4) - Remove and DISCARD
- Remove retainers as needed.
Battery Tray Bolt (1) - Remove [7x]
Remove retainers as needed.
- Battery Tray (1) - Remove
Exhaust Pipe Clamp (1) - Loosen
Exhaust Gas Temperature Sensor- Position 1 (1) - Remove and position aside
Exhaust Gas Temperature Sensor- Position 2 (1) - Remove and position aside
Emission Reduction Fluid Exhaust Front Pipe Injector Supply Pipe Insulator (1) - Remove
Emission Reduction Fluid Injector Clamp (1) - Remove and DISCARD
- Reductant Fluid Injector (2) - Reposition
- Exhaust System Front Gasket (3) - Remove and DISCARD
- Clean the exhaust mounting flange and injector mounting surfaces to remove any soot or emission reduction fluid deposits.
Exhaust Gas Temperature Sensor- Position 3 (1) - Remove and position aside
Using a suitable tool, remove the position 2 nitrogen oxides sensor (1) from the nitrogen oxides catalytic converter.
Using a suitable tool, remove the position 3 nitrogen oxides sensor (1) from the nitrogen oxides catalytic converter.
Using a suitable tool, remove the exhaust particulate matter sensor (1) from the nitrogen oxides catalytic converter.
Exhaust Pipe Clamp (1) - Loosen
Exhaust Front Pipe Nut (1) - Remove [2x]
Catalytic Converter Brace Bracket Nut (1) - Remove [2x]
- Wiring Harness Retainer (2) @Catalytic Converter Brace Bracket (3) - Remove
- Catalytic Converter Brace Bracket (3) - Remove
Exhaust Front Pipe Nut (1) - Remove [2x]
Nitrogen Oxides Catalytic Converter (1) - Remove
- Exhaust System Front Gasket (2) - Remove and DISCARD
Electrical Connector (1) @Exhaust Back Pressure Valve - Disconnect
Exhaust Gas Recirculation Coolant Return Pipe Bolt (1) - Remove [2x]
- Exhaust Gas Recirculation Valve Cooling Return Hose (2) - Remove
- Turbocharger Coolant Feed and Return Pipe Gasket (3) - Remove and DISCARD
Catalytic Converter Nut (1) - Remove [3x]
Exhaust Back Pressure Valve (1) - Remove
- Exhaust Gas Recirculation Valve Inlet Gasket (2) - Remove and DISCARD
Hose Clamp (1) - Disengage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Exhaust Gas Recirculation Coolant Return Pipe (3) @Exhaust Gas Recirculation Pipe Clip (2) - Remove
- Exhaust Gas Recirculation Coolant Return Pipe (3) - Remove
Exhaust Gas Recirculation Pipe Bracket Bolt (1) - Remove
- Exhaust Gas Recirculation Pipe Bracket (5) - Remove
- Disconnect electrical connectors, reposition harness and hoses as needed.
Hose Clamp (1) - Disengage [3x] - Hose Clamp Replacement Guidelines - Spring Type
- Heater Inlet Hose (3) @Exhaust Gas Recirculation Cooler Inlet Pipe - Remove
- Exhaust Gas Recirculation Cooler Outlet Pipe (4) @Exhaust Gas Recirculation Cooler Inlet Pipe - Remove
- Exhaust Gas Recirculation Cooler Inlet Pipe (5) @Exhaust Gas Recirculation Cooler Inlet Pipe - Remove
Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Thermostat Bypass Hose (2) @Exhaust Gas Recirculation Cooler Inlet Pipe - Remove
Hose Clamp (1) - Disengage [3x] - Hose Clamp Replacement Guidelines - Spring Type
- Exhaust Gas Recirculation Valve Cooling Feed Hose (2) @Exhaust Gas Recirculation Cooler Inlet Pipe - Remove
- Exhaust Gas Recirculation Valve Cooling Return Hose (3) @Exhaust Gas Recirculation Cooler Inlet Pipe - Remove
- Turbocharger Coolant Feed and Return Pipe (4) @Exhaust Gas Recirculation Cooler Inlet Pipe - Remove
Exhaust Gas Recirculation Pipe Bracket Bolt (1) - Remove [2x]
Exhaust Gas Recirculation Cooler Inlet Pipe (1) - Remove
Exhaust Pressure Differential Sensor Bracket Stud (1) - Remove [2x]
- Exhaust Pressure Differential Sensor Bracket (2) - Reposition
Disengage the exhaust pressure differential sensor hose clamp (1) and remove the exhaust pressure differential sensor from the exhaust gas recirculation valve hose. Hose Clamp Replacement Guidelines - Spring Type
Disengage the exhaust pressure differential sensor hose clamp (1) and remove the exhaust pressure differential sensor at the exhaust gas recirculation cooler. Hose Clamp Replacement Guidelines - Spring Type
Disengage the 2 exhaust pressure differential sensor hose clamps (1) and remove the 2 exhaust pressure differential sensor hoses at the exhaust gas recirculation cooler. Hose Clamp Replacement Guidelines - Spring Type
Exhaust Gas Recirculation Pipe Nut (1) - Remove
Exhaust Gas Recirculation Pipe Nut (1) - Remove
Exhaust Gas Recirculation Valve Bracket Nut (1) - Remove
- Heater Inlet Hose Bracket (2) - Reposition
Disconnect the electrical connector (1).
- Exhaust Gas Recirculation Pipe Bolt (2) - Remove [2x]
Exhaust Gas Recirculation Pipe Bolt (1) - Remove [2x]
Remove the exhaust gas recirculation valve (1) with the exhaust gas recirculation valve hose.
- Exhaust Gas Recirculation Valve Cooler Gasket (2) - Remove and DISCARD
Exhaust Gas Recirculation Pipe (1) - Reposition
- Exhaust Gas Recirculation Outlet Pipe Gasket (2) - Remove and DISCARD
Exhaust Gas Recirculation Cooler Inlet Pipe Bolt (1) - Remove [4x]
- Exhaust Gas Recirculation Pipe (2) - Remove
- Exhaust Gas Recirculation Cooler Inlet Pipe Gasket (3) Remove and DISCARD [2x]
Disconnect the electrical connector at exhaust gas recirculation cooler.
- Exhaust Gas Recirculation Cooler Nut (1) - Remove [4x]
Remove the exhaust gas recirculation cooler (1).
Catalytic Converter Brace Bracket Nut (1) - Remove [2x]
Catalytic Converter Brace Bracket Nut (1) - Loosen [2x]
Fuel Heater Inlet and Outlet Nut (1) - Remove
- Fuel Cooler Coolant Cooler Inlet Hose - Reposition
Engine Wiring Harness Ground Bolt (1) - Remove
- Ground Cable (2) - Position aside
Catalytic Converter Brace Bracket Nut (1) - Loosen [2x]
- Reposition hoses and wiring harness as needed.
Nitrogen Oxides Catalytic Converter (1) - Remove
- Catalytic Converter Clamp (2) - Remove and DISCARD
- Catalytic Converter Gasket (3) - Remove and DISCARD
- NOTE:
Components removed for graphic clarity.
Starter Heat Shield Bolt (3) - Remove [2x]
- Disengage the starter heat shield (2) from the retainer (1).
Starter Heat Shield (1) - Remove
Starter Solenoid Cable Nut (1) - Remove
- Wiring Harness Conduit Nut (2) - Remove
- Starter Solenoid Cable (3) - Remove
Starter Bolt (1) - Remove [3x]
- Reposition the starter (2) to access the electrical connector.
Reposition the protective sleeve (2).
- Electrical Connector (1) - Disconnect
Remove the starter (1) through the wheel well.
Hose Clamp (1) - Disengage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Outlet Hose (2) @Water Pump Inlet Pipe - Remove
- Heater Water Auxiliary Pump Hose (3) @Water Pump Inlet Pipe - Remove
Transmission Fluid Cooler Pipe Nut (1) - Remove
- Transmission Fluid Cooler Inlet and Outlet Pipe (2) Position aside
Heater Inlet Pipe Bracket Stud (1) - Remove
- Position the heater coolant pump and heater water auxiliary pump bracket assembly (2) aside.
Engine Wiring Harness Ground Nut (2) - Remove
- Starter Solenoid Cable (1) - Remove
Engine Front Cover Bolt (1) - Remove
- Engine Front Cover (2) - Remove
Rotate the accessory drive primary belt tensioner (1) clockwise to release the drive belt tension.
- Slide the accessory drive primary belt (2) off of the belt idler pulley and slowly release the accessory drive primary belt tensioner (1).
- Remove the accessory drive primary belt (2) from the vehicle.
Engine Front Cover Stud (1) - Remove [3x]
Belt Idler Pulley (1) - Remove
Drive Belt Tensioner Bolt (1) - Remove [2x]
- Drive Belt Tensioner (2) - Remove
Radiator Inlet Hose Clip (1) - Unclip
- Engine Wiring Harness Retainer (2) - Remove [2x]
- Engine Wiring Harness Bracket Bolt (3) - Remove
- Engine Wiring Harness Bracket (4) - Remove
Electrical Connector (1) - Disconnect
Battery Positive Cable Nut (1) @Generator (4) - Remove
- Generator Battery Jumper Cable (2) - Remove
Generator Bolt (2) - Loosen until disengaged
- Generator Bolt (1) - Remove
- Reposition hoses and wiring harness as needed.
Generator (1) - Remove
Electrical Connector (1) - Disconnect [2x]
Air Conditioning Compressor Nut (1) - Remove
- Air Conditioning Compressor and Condenser Hose (2) - Remove
- Air Conditioning Compressor and Condenser Hose Seal- Large (3) - Remove and DISCARD
- Air Conditioning Compressor and Condenser Hose Seal- Small (4) - Remove and DISCARD
Air Conditioning Compressor Nut (1) - Remove
- Air Conditioning Compressor Stud (2) - Remove
Air Conditioning Compressor Bolt (1) - Remove
Air Conditioning Compressor Bolt (1) - Remove
Air Conditioning Compressor (1) - Remove
Engine Wiring Harness Bracket Nut (1) - Remove [2x]
- Engine Wiring Harness Bracket (2) - Reposition
Oil Level Indicator Tube Stud (1) - Remove
- Clip (2) @Oil Level Indicator Tube - Remove
Oil Level Indicator Tube Bolt (1) - Remove
Oil Level Indicator Tube (1) @Lower Crankcase Extension - Remove
- Oil Level Indicator Seal (2) - Remove and DISCARD
Hose Clamp (1) - Disengage [4x] - Hose Clamp Replacement Guidelines - Spring Type
- Thermostat Bypass Hose (5) @Engine Coolant Flow Control Valve - Remove
- Engine Oil Cooler Coolant Inlet Hose (4) @Engine Coolant Flow Control Valve - Remove
- Thermostat Bypass Hose (3) @Engine Coolant Flow Control Valve - Remove
- Radiator Inlet Hose (2) @Engine Coolant Flow Control Valve - Remove
Engine Coolant Heater Cord (1) @Engine Coolant Heater - Disconnect
- Engine Coolant Heater Cord Retainer (3) - Disconnect
- Engine Coolant Heater Cord (1) - Reposition away
Reposition hoses and hose clips as needed.
- Electrical Connector (1) @Engine Coolant Flow Control Valve - Disconnect [3x]
Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Engine Coolant Air Bleed Hose Stud (2) - Remove
- Thermostat Bypass Hose (3) - Remove
Thermostat Bypass Pipe Bolt (2) - Remove
- Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Exhaust Gas Recirculation Coolant Return Pipe (3) - Remove
Thermostat Bypass Hose Clamp (1) - Disengage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Engine Oil Cooler Coolant Inlet Hose Clamp (2) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Engine Oil Cooler Coolant Outlet Hose (3) @Engine Oil Cooler - Remove
- Automatic Transmission Fluid Cooling Heat Exchanger Outlet Hose (4) @Engine Oil Cooler - Remove
- Engine Oil Cooler Coolant Inlet Hose (5) @Engine Oil Cooler - Remove
Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Thermostat Bypass Hose (2) @Thermostat Bypass Pipe - Remove
Engine Wiring Harness Ground Bolt (1) - Remove
- Ground Cable (2) - Position aside
Fuel Feed Pipe Clip Bolt (1) - Remove
Fuel Pump Fuel Feed Hose (1) @High Pressure Diesel Fuel Pump - Disconnect - Metal Collar Quick Connect Fitting Service
Fuel Return Pipe (1) @Diesel Fuel Separator - Disconnect - Metal Collar Quick Connect Fitting Service
- Disconnect the remaining wiring harness connectors and retainers as needed on the left side of the engine and position the engine wiring harness aside.
Fuel Heater Inlet and Outlet Nut (1) - Loosen
- Fuel Heater Inlet and Outlet Bolt (2) - Remove
- Reposition the fuel heater inlet and outlet hoses aside.
Transmission Cooler Bypass Valve Bracket Bolt (1) - Remove
Fuel Heater Inlet and Outlet Bolt (3) - Remove
- Retainer (1) - Remove [2x]
Automatic Transmission Fluid Cooling Exchanger Nut (2) - Remove
- Automatic Transmission Fluid Cooling Exchanger Bolt (1) - Remove [2x]
Automatic Transmission Fluid Cooling Exchanger (1) - Position aside
Install the EN-52579 Crankshaft Rotator (1).
Repeat the following steps for all transmission torque converter bolts (1) :
- Using the EN - 52579 Crankshaft Rotator, rotate the crankshaft balancer clockwise ONLY, to align the torque converter bolt with the starter opening.
- Transmission Torque Converter Bolt (1) - Remove [6x]
Remove the EN-52579 Crankshaft Rotator (1).
Remove the 4 wiring harness retainers (3), then reposition the wiring harness as necessary.
- Support the transmission with a suitable transmission jack.
Transmission Mount Nut (1) - Remove
- Transmission Support Crossmember Nut (2) - Remove [4x]
- Transmission Support Crossmember Bolt (3) - Remove [4x]
Transmission Support Crossmember (1) - Remove
- Lower the transmission to gain access to the top and sides of the transmission.
Fuel Feed and Return Front Hose Bracket Nut (1) - Remove
Retainer (2) - Remove
Fuel Cooler Support Bracket Bolt (1) - Remove [2x]
- Fuel Cooler Bolt (2) - Remove
- Reposition the fuel lines with the fuel cooler (3).
Remove the transmission vent hose retainer from the transmission (1).
- Transmission Vent Hose (2) @Transmission - Remove
- CAUTION:
Carefully remove the engine wiring harness channel from the transmission stud. If the engine wiring harness channel is damaged during removal, replace the engine wiring harness channel. Failure to replace the channel may lead to harness damage.
Carefully remove the engine wiring harness channel (1) from the transmission stud and position aside.
Transmission Stud (1) - Remove [4x]
- Raise the transmission into place.
Transmission Support Crossmember (1) - Install
Transmission Support Crossmember Bolt (3) - Install [4x]
- Transmission Support Crossmember Nut (2) - Install and hand tighten
- Remove the transmission jack.
Transmission Bolt (2) - Remove
- Transmission Stud (1) - Remove
Transmission Stud (1) - Remove [2x]
- Lower the vehicle and support the transmission bell housing with a suitable block of wood and floor jack.
Transmission Bolt (1) - Remove
Use a floor jack to raise the transmission to install the rear engine lift hook set bolts.
- Install the EN-52474 Engine Lift Hook Set (1).
Remove and DISCARD the 3 left side engine mount frame side bolts (1).
Remove and DISCARD the 3 right side engine mount frame side bolts (1).
- Ensure that all electrical connectors are disconnected at this time.
- Using a suitable engine lifting device, remove the engine from the vehicle.
Install the EN-21366 Converter Holding Strap (1) onto the transmission bell housing to retain the torque converter.
Left side shown, right side similar.
The hoses do NOT need to be removed from the charge air cooler surge tank (2).
Do not use a prying tool to remove the injector.
After removing the injector, wipe any residual DEF with a clean towel to avoid urea crystal build up at the connection during installation. Urea crystal build-up can result in a future leak.