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
Front Bumper Fascia Skid Plate Bolt (1) - Remove [4x]
- Underbody Skid Shield Bolt (2) - Remove [4x]
Underbody Splash Shield (1) - Remove
- NOTE:
The proper position of the underbody skid shield is between the front bumper fascia extension and the front frame.
Underbody Skid Shield Bolt (2) - Remove [2x]
- Underbody Skid Shield (3) - Remove
- Drain the engine oil. Engine Oil and Oil Filter Replacement
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 (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).
- Remove 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.
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
- 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.
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 Wiring Harness Bracket Nut (1) - Remove [2x]
- Engine Wiring Harness Bracket (2) - Reposition
Engine Oil Level Indicator (1) - Remove
Oil Level Indicator Tube Stud (1) - Remove
- Clip (2) @Oil Level Indicator Tube - Remove
Oil Level Indicator Tube Bolt (1) - Remove
- With aid of assistant reposition the engine wiring harness and note the routing of oil level indicator tube.
Oil Level Indicator Tube (1) - Remove
- Oil Level Indicator Seal (2) - Remove and DISCARD
Engine Coolant Air Bleed Hose Stud (2) - Remove
- Thermostat Bypass Hose (1) - Reposition
Thermostat Bypass Pipe Bolt (3) - Remove
- Exhaust Gas Recirculation Coolant Return Pipe (2) - Reposition
Hose Clamp (1) - Disengage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Hose Clamp (2) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Engine Oil Cooler Coolant Outlet Hose (4) @Engine Oil Cooler - Remove
- Automatic Transmission Fluid Cooling Heat Exchanger Outlet Hose (5) @Engine Oil Cooler - Remove
- Engine Oil Cooler Coolant Inlet Hose (3) @Engine Oil Cooler - Remove
Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Thermostat Bypass Hose (2) @Thermostat Bypass Pipe - 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) Position aside
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
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).
{ If equipped }Transfer Case Skid Shield Bolt (1) - Remove [3x]
- { If equipped }Transfer Case Skid Shield (2) - Remove
Transfer Case Front Output Shaft Boot Clamp (1) @Front Axle Propeller Shaft - Remove and DISCARD
- Reposition the transfer case front output shaft boot (2) and mark a reference point between the front axle propeller shaft and the transfer case front output shaft.
Front Axle Propeller Shaft (1) - Remove
Mark the relationship of the propeller shaft to the differential drive pinion gear yoke.
- Rear Propeller Shaft Bolt (1) - Remove [4x]
Propeller Shaft (1) - Remove
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 [2x]
Transmission Support Crossmember Nut (1) - Remove [4x]
- Transmission Support Crossmember Bolt (2) - Remove [4x]
Transmission Support Crossmember (1) - Remove
- Lower the transmission to gain access to the top and sides of the transmission.
Transmission Mount Bolt (1) - Remove [2x]
- Transmission Mount (2) - Remove
Disconnect the wiring harness retainers.
- Catalytic Converter Brace Bracket Bolt (1) - Remove [2x]
- Exhaust Front Bracket (2) - Remove
Transmission Heat Shield Bolt (2) - Remove
- Transmission Heat Shield Bolt (1) - Remove [2x]
- Transmission Heat Shield (3) - Remove
- Disconnect the wiring harness retainers.
Disconnect the transfer case two/four wheel drive actuator electrical connector (1).
- Disconnect the transfer case two/four wheel drive actuator position sensor electrical connector (2).
- Remove the wiring harness retainer (3) from the transfer case and position the wiring harness out of the way.
Transfer Case Vent Hose (1) - Remove
- Using a suitable transmission jack, support the transfer case.
- Using suitable straps or chains, secure the transfer case to the transmission jack.
Transfer Case Nut (1) - Remove [6x]
- Transfer Case (2) - Remove
- Transfer Case Adapter Gasket (3) - Remove and DISCARD
- Disconnect the wiring harness retainers.
Fuel Heater Inlet and Outlet Nut (1) @Transmission - Remove
Fuel Heater Inlet and Outlet Bolt (1) @Transmission - Remove
- Reposition the fuel heater inlet and outlet hoses aside.
Transmission Fluid Cooler Pipe Nut (1) - Remove
Transmission Fluid Cooler Inlet and Outlet Pipe (1) - Reposition
- Transmission Fluid Cooler Pipe Seal (2) - Remove and DISCARD [2x]
- Cap the fittings and plug the holes when removing the transmission fluid cooler pipes.
Automatic Transmission Fluid Cooling Exchanger Bolt (1) - Remove [2x]
- Transmission Fluid Cooler Pipe Bolt (2) - Remove
- Automatic Transmission Fluid Cooling Exchanger Nut (3) - Remove
- Reposition the transmission fluid cooling exchanger with automatic transmission fluid cooler inlet and outlet pipes (4) away from the transmission as necessary and secure using a suitable strap or wire.
- Transmission Fluid Cooler Seal (5) - Remove and DISCARD
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
Remove the transfer case vent hose retainer (1) from the fuel feed and return pipe.
- Transfer Case Vent Hose (2) @Transfer Case - Remove
Disconnect the transmission wiring harness connector (1).
- Remove the 2 wiring harness retainers (2) and reposition the wiring harness as necessary.
- 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]
Transmission Bolt (2) - Remove
- Transmission Stud (1) - Remove
Transmission Stud (1) - Remove [2x]
Transmission Bolt (1) - Remove
Automatic Transmission (1) - Remove
Install the EN - 21366 Converter Holding Strap (1) onto the transmission bell housing to retain the torque converter.
Front Stabilizer Shaft Link Nut - Right Side (1) - Remove
- Front Stabilizer Shaft Link - Right Side@Lower Control Arm - Remove
Front Stabilizer Shaft Link Nut - Left Side (1) - Remove
- Front Stabilizer Shaft Link - Left Side@Lower Control Arm - Remove
- NOTE:
Support the front stabilizer shaft (3).
Front Stabilizer Shaft Bolt (1) - Remove [4x]
- Front Stabilizer Shaft Clamp (2) - Remove [2x]
- Front Stabilizer Shaft (3) - Remove
- Have an assistant apply the brakes.
- 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 - Left Side (1) - Remove and DISCARD
Install the DT - 45859 Axle Remover (2) to the front wheel hub and hand tighten the 2 wheel nuts (1).
- 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 DT - 45859 Axle Remover (2) from the front wheel hub.
- 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 - Right Side (1) - 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 - Left Side (1) - Remove
- NOTE:
Only the left front wheel is equipped with the front disc brake pad wear sensor (1).
Front Disc Brake Pad Wear Sensor (1) @Front Brake Caliper - Remove
Front Brake Caliper Bolt - Left Side (2) - Remove [2x]
- Remove the brake caliper and support with heavy mechanics wire. (1)
Front Wheel Speed Sensor Bolt - Left Side (1) - Remove
- Front Wheel Speed Sensor - Left Side (2) - Remove
- Front Wheel Speed Sensor Bracket Bolt - Left Side (3) - Remove
- Remove the left side front wheel speed sensor bracket (4).
Front Wheel Speed Sensor Bracket Bolt - Left Side (1) - Remove
- Remove the front wheel speed sensor wiring harness bracket (2).
Steering Linkage Outer Tie Rod Nut - Left Side (1) - Remove
- 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.
Using CH - 43631 Ball Joint Separator (1), remove the left side steering linkage outer tie rod from the steering knuckle.
- Support the left side lower control arm with a suitable jack stand.
Front Upper Control Arm Ball Stud Nut - Left Side (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 - Left Side (1) - Remove
- {If Equipped} Disconnect the electrical connector at the shock absorber.
Unclip and reposition the chassis wiring harness bracket (1) away from the frame shock tower.
Front Shock Absorber Nut - Left Side (1) - Remove [3x]
Front Shock Absorber Bolt - Left Side (1) - Remove [2x]
- Remove the jack stand from under the front suspension lower control arm.
Front Shock Absorber - Left Side (1) - Remove
- 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.
Using a suitable flat bladed tool (1), release the front wheel drive half shaft (2) from the front differential carrier.
- NOTE:
Some components not shown for graphic clarity.
Front Wheel Drive Half Shaft - Left Side (1) - Remove
Front Wheel Drive Shaft Retaining Ring (1) - Remove and DISCARD
- Front Wheel Drive Shaft Seal (2) - Remove and DISCARD
Front Brake Hose Bracket Bolt - Right Side (1) - Remove
Front Brake Caliper Bolt - Right Side (2) - Remove [2x]
- Remove the brake caliper and support with heavy mechanics wire. (1)
Front Wheel Speed Sensor Bolt - Right Side (1) - Remove
- Front Wheel Speed Sensor - Right Side (2) - Remove
- Front Wheel Speed Sensor Bracket Bolt - Right Side (3) - Remove
- Remove the right side front wheel speed sensor bracket (4).
Front Wheel Speed Sensor Bracket Bolt - Right Side (1) - Remove
- Remove the front wheel speed sensor wiring harness bracket (2).
Steering Linkage Outer Tie Rod Nut - Right Side (1) - Remove
- 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.
Using CH - 43631 Ball Joint Separator (1), remove the right side steering linkage outer tie rod from the steering knuckle.
- Support the right side lower control arm with a suitable jack stand.
Front Upper Control Arm Ball Stud Nut - Right Side (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 - Right Side (1) - Remove
- 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.
Using a suitable flat bladed tool (1), release the front wheel drive half shaft (2) from the front differential carrier.
- NOTE:
Remove from axle side first
Front Wheel Drive Half Shaft - Right Side (1) - Remove
Front Wheel Drive Shaft Retaining Ring (1) - Remove and DISCARD
- Front Wheel Drive Shaft Seal (2) - Remove and DISCARD
Disconnect the front drive axle actuator electrical connector (1).
- Release the two harness retainers (2) and reposition harness.
Front Differential Carrier Nut (1) - Remove
- Front Differential Carrier Bolt (2) - Remove and DISCARD
- Support the differential carrier with a suitable jack.
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
Thermostat Bypass Pipe Bolt (3) - Remove [2x]
- Thermostat Bypass Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Thermostat Bypass Hose (2) - Remove
- Engine Coolant Thermostat Gasket (4) - Remove and DISCARD
Reposition the electrical harness from the engine coolant air bleed hose stud.
- Thermostat Bypass Pipe Bolt (1) - Remove [2x]
- Engine Coolant Air Bleed Hose Stud (2) - Remove
Thermostat Bypass Hose (2) - Reposition
- Engine Coolant Thermostat Gasket (1) - Remove and DISCARD
Engine Oil Cooler Bolt (1) - Remove [5x]
Engine Oil Cooler - (1) Remove
- Engine Oil Cooler Gasket - Large (2) - Remove and DISCARD
- Engine Oil Cooler Gasket - Small (3) - Remove and DISCARD
Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Thermostat Bypass Hose (2) @Thermostat Bypass Pipe - Remove
Install the EN - 49979 Crankshaft Holder (1) with EN - 956 - 1 Extension (3).
Automatic Transmission Flex Plate Bolt (2) - Remove and DISCARD [8x]
- Automatic Transmission Flex Plate (1) - Remove
Crankshaft Pulley Bolt (2) - Loosen [4x]
- Remove the EN - 49979 Crankshaft Holder (1) with EN - 956 - 1 Extension (3).
Crankshaft Pulley Bolt (2) - Remove [4x]
- Crankshaft Pulley (1) - Remove
Engine Front Cover Bolt (1) - Remove [8x]
- Crankshaft Front Oil Seal (2) - Remove and DISCARD
Remove the 16 timing chain cover bolts (1, 2).
- Reposition hoses and pipes as needed.
- NOTE:
Avoid prying close to the transmission pins.
Using a suitable tool at the locations indicated by the arrows to pry, loosen the timing chain lower cover (1) carefully from the engine block.
Timing Chain Lower Cover (1) - Remove
- NOTE:
Use a suitable rubber or plastic mallet to remove the crankshaft rear oil seal.
Crankshaft Rear Oil Seal (1) - Remove and DISCARD
Install the EN - 47634 Holder (1) with the EN - 956 Extension (4) to the oil pump sprocket (2).
- Hold the EN - 956 Extension (4) and loosen the oil pump sprocket bolt (3).
- Remove the EN - 47634 Holder (1) and the EN - 956 Extension (4).
Oil Pump Sprocket Bolt (1) - Remove
- Oil Pump Sprocket (2) - Remove
- Timing Belt (3) - Remove
Oil Pan Bolt (1) - Remove [23x]
- NOTE:
Ensure that the two lower crankcase extension pins do not get damaged while loosening.
Use the EN - 37228 Separating Tool or equivalent tool, carefully loosen the lower oil pan (1) evenly all the way around. Avoid the locations near the lower crankcase extension pins.
- Lower Oil Pan (1) - Remove and DISCARD
Oil Pump Suction Pipe Bolt (1) - Remove
- Oil Pump Suction Pipe (2) - Remove
- Oil Pump Suction Pipe Gasket (3) - Remove and DISCARD
- Disconnect the electrical connectors and release the wiring harness retainers as necessary.
- NOTE:
Components MUST be separated, marked, or organized in a way to ensure the installation to their original location and position. Take precautions in order to prevent interchanging of parts.
Lower Crankcase Extension Bolt - M6 (1) - Remove
- Lower Crankcase Extension Bolt - M6 (2) - Remove [12x]
- Lower Crankcase Extension Bolt - M6 (3) - Remove
- Lower Crankcase Extension Bolt - M8 (4) - Remove and DISCARD [7x]
- NOTE:
Ensure that the two lower crankcase extension pins (2, 4) do NOT get damaged while loosening.
Using the EN - 37228 Separating Tool (3), carefully loosen the lower crankcase extension (1) evenly all the way around. Avoid the lower crankcase extension pin locations.
- NOTE:
Pry carefully at the locations as shown (1, 3).
Lower Crankcase Extension (2) - Remove
- Upper Oil Pan Gasket (4) - Remove and DISCARD
- Oil Pump Gasket (5) - Remove and DISCARD
Engine Front Cover Bracket Bolt (1) - Remove [2x]
- Timing Indicator Bracket (2) - Remove
Thermostat Bypass Pipe Bolt (7, 9) - Remove [4x]
- Thermostat Bypass Hose (6, 10) - Remove [2x]
- Engine Coolant Thermostat Gasket (5, 8) - Remove and DISCARD [2x]
Oil Filter Bypass Valve (4) - Remove
- Engine Oil Temperature Sensor (1) - Remove
- Engine Oil Pressure Sensor (5) - Remove
- Clean and inspect all mating surfaces.
Left side shown, right side similar.
The hoses do NOT need to be removed from the charge air cooler surge tank (2).
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.
Support the lower control arm to prevent over - articulation of the front lower control arm ball joint.
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.
Support the lower control arm to prevent over - articulation of the front lower control arm ball joint.
Ensure that the front axle is securely attached to the hydraulic jack.
The front axle may have to be maneuvered to remove it from the vehicle.
It is likely you will bend the crankshaft front oil seal during the removal. Use care to not damage the engine block.