Removal Procedure
- Place the air system in service mode.
- Raise the vehicle until the tires are off the ground. Lifting and Jacking the Vehicle
- Using the scan tool, deflate the air spring that will be serviced.
- Relieve the fuel system pressure. Fuel Pressure Relief
- Drain the cooling system. Cooling System Draining and Filling (GE 47716 L84, L87) , or Cooling System Draining and Filling (Static L84, L87)
- Recover the refrigerant. Refrigerant Recovery and Recharging
- Remove the negative battery cable from the battery. Battery Negative Cable Disconnection and Connection (KL9)
Air Cleaner Outlet Duct Clamp (1) - Loosen
- Disconnect the mass airflow sensor electrical connector (2) and remove all engine wiring harnesses from the air cleaner assembly.
Air Cleaner Outlet Duct (1) - Reposition away
- Air Cleaner Nut (2) - Remove
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
Intake Air Duct Retainer (1) - Remove
Air Cleaner Assembly (1) - Remove
Air Cleaner Outlet Duct Bracket Bolt (1) - Remove
- Remove the engine wiring harness from the air cleaner outlet duct bracket.
Positive Crankcase Ventilation Fresh Air Tube (3) - Disconnect - Plastic Collar Quick Connect Fitting Service
- Air Cleaner Outlet Duct Clamp (2) - Loosen
- Air Cleaner Outlet Duct (1) - Remove
Radiator Surge Tank Inlet Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Surge Tank Inlet Hose (2) @ Engine Radiator - Remove and position aside
Front End Sheet Metal Diagonal Brace Bolt (1) @ Upper Tie Bar - Remove [ 4x ]
- Front End Sheet Metal Diagonal Brace (2) @ Upper Tie Bar - Remove [ 2x ]
Release the 6 integral retaining features (1).
- Radiator Air Upper Baffle (2) - 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
- Remove the engine wiring harness fuse block bracket.
Radiator Surge Tank Outlet Hose Clip (2) - Remove [ 2x ]
- Radiator Surge Tank Outlet Hose (3) - Reposition
- NOTE:
Some components not shown for graphic clarity.
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
- NOTE:
Some components not shown for graphic clarity.
Wiring Harness Retainer (1) - Remove [ 2x ]
- Electrical Connector (3) - Disconnect
- Wiring Harness (2) - Position aside
- NOTE:
Some components not shown for graphic clarity.
Wiring Harness Retainer (2) - Remove [ 2x ]
- Electrical Connector (1) - Disconnect
- Wiring Harness (3) - Position aside
Engine Oil Cooler Hose Clip (1) - Release
Engine Oil Cooler Retainer (2) - Remove [ 2x ]
- Engine Oil Cooler Pipe Bracket Bolt (3) - Remove
- Engine Oil Cooler Hose (1) @ Engine Radiator - Remove [ 2x ]
- NOTE:
Some components not shown for graphic clarity.
Radiator Air Side Baffle Retainer (1) - Remove [ 4x ]
- Radiator Air Side Baffle - Right Side (2) - Reposition
Radiator Air Side Baffle Retainer (2) - Remove
- Radiator Air Side Baffle - Left Side (1) - Reposition
Transmission Fluid Cooler Pipe Bolt (1) - Remove
- Transmission Fluid Cooler Pipe Clip (2) - Remove [ 2x ]
Transmission Fluid Cooler Pipe Nut (1) - Remove
- Transmission Fluid Cooler Inlet and Outlet Pipe (2) @ Transmission Fluid Auxiliary Cooler - Remove and position aside
- Transmission Fluid Cooler Pipe Fitting Seal (3) - Remove and DISCARD
Transmission Fluid Cooler Pipe Nut (1) - Remove
Transmission Fluid Cooler Inlet and Outlet Pipe (1) @ Transmission Fluid Auxiliary Cooler - Remove and position aside
- Transmission Fluid Cooler Pipe Fitting Seal (2) - Remove and DISCARD
Transmission Fluid Cooler Pipe Clip (1) - Release
Radiator Inlet Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Outlet Hose (2) @ Engine Radiator - Remove
Air Conditioning Compressor and Condenser Hose Nut (1) - Remove
- Air Conditioning Condenser and Evaporator Hose Nut (2) - Remove
Air Conditioning Compressor and Condenser Hose (1) @ Air Conditioning Condenser - Remove
- Air Conditioning Condenser and Evaporator Hose (3) @ Air Conditioning Condenser - Remove
- Air Conditioning Compressor and Condenser Hose Seal (2) - Remove and DISCARD [ 2x ]
Rotate the top of the condenser, fan and radiator assembly (1) rearward and lift it out of the engine compartment.
Plenum Front Panel Outer Reinforcement (1) - Remove - Plenum Front Panel Outer Reinforcement Removal and Installation
- NOTE:
The accessory drive primary belt is not reusable.
Using a suitable tool, cut the accessory drive primary belt (1).
- Accessory Drive Primary Belt (1) - Remove and DISCARD
- NOTE:
The accessory drive auxiliary belt is not reusable.
Using a suitable tool, cut the accessory drive auxiliary belt (1).
- Accessory Drive Auxiliary Belt (1) - Remove and DISCARD
Battery Positive Cable Nut (1) - Remove
- Starter Solenoid Cable (2) - Remove
- Electrical Connector (3) - Disconnect
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
- NOTE:
It is not necessary to recover and recharge the refrigerant to perform this repair.
Air Conditioning Compressor Bolt (1) - Remove
- Air Conditioning Compressor Nut (2) - Remove
- Air Conditioning Compressor Stud (3) - Remove
Air Conditioning Compressor (1) - Position aside
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 ]
- NOTE:
Some components not shown for graphic clarity.
Positive Crankcase Ventilation Tube Connector (1) @ Positive Crankcase Ventilation Fitting - Disconnect - Plastic Collar Quick Connect Fitting Service
- Positive Crankcase Ventilation Tube Connector (2) @ Intake Manifold - Disconnect - Plastic Collar Quick Connect Fitting Service
- Positive Crankcase Ventilation Foul Air Tube (3) - Remove
Evaporative Emission Canister Purge Tube Connector (1) @ Evaporative Emission Canister Purge Solenoid Valve - Disengage - Plastic Collar Quick Connect Fitting Service
- Evaporative Emission Canister Purge Tube (2) @ Evaporative Emission Canister Purge Solenoid Valve - Remove and position aside
Remove the oil level indicator. (1)
Grasp the valve rocker arm cover insulator (3) and lift up disengaging the 3 upper intake manifold sight shield grommets (2) from the 3 valve rocker arm cover insulator retainers (1).
- Valve Rocker Arm Cover Insulator- Left Side (3) - Remove
- Inspect the 3 upper intake manifold sight shield grommets (2) on the valve rocker arm cover insulator and replace as necessary.
Grasp the valve rocker arm cover insulator (3) and lift up disengaging the 3 upper intake manifold sight shield grommets (1) from the 3 valve rocker arm cover insulator retainers (2).
- Valve Rocker Arm Cover Insulator- Right Side (3) - Remove
- Inspect the 3 upper intake manifold sight shield grommets (1) on the valve rocker arm cover insulator (3) and replace as necessary.
Engine Wiring Harness Connector (1) @ Throttle Body - Disconnect
- Engine Wiring Harness Retainer (2) @ Intake Manifold Cover - Remove [ 2x ]
- Engine Wiring Harness Connector (3) @ Manifold Absolute Pressure Sensor - Disconnect
- Engine Wiring Harness Connector (4) @ Evaporative Emission Canister Purge Solenoid Valve - Disconnect
Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) - Remove [ 4x ]
Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) - Remove [ 3x ]
- NOTE:
Some components not shown for graphic clarity.
Loosen the 10 intake manifold bolts (1) until the bolts are no longer threaded into the cylinder heads.
- Move the intake manifold and intake manifold cover (2) forward enough to gain access to the rear engine wiring harness retainers.
Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) - Remove [ 4x ]
- NOTE:
The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness.
Remove the intake manifold and intake manifold cover (1) as an assembly.
- Cover the cylinder head passages in order to prevent dirt or debris from entering the passages.
Intake Manifold Gasket (1) - Remove and DISCARD [ 8x ]
Oil Level Indicator Tube Bolt (1) - 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
Valve Rocker Arm Oil Control Valve Extension Harness (1) @ Valve Rocker Arm Oil Control Valve Harness - Disconnect
- NOTE:
Some components not shown for graphic clarity.
Engine Wiring Harness Bolt (1) - Remove [ 2x ]
Wiring Harness Retainer (1) - Remove
Engine Wiring Harness Bracket Bolt (1) - Remove
Engine Wiring Harness - Reposition
- Engine Wiring Harness Connector (1) @ Ignition Coil - Disconnect [ 8x ]
- WARNING:
Refer to Diesel/Gasoline Vapors Warning .
Fuel Feed Pipe (1) - Disconnect - Metal Collar Quick Connect Fitting Service
- Fuel Feed Pipe (1) - Reposition
Fuel Feed Pipe Bolt (1) - Remove
- Fuel Feed Pipe (2) - Disconnect - Metal Collar Quick Connect Fitting Service
- Fuel Feed Pipe (2) - Reposition
- CAUTION:
Fuel feed intermediate pipes will be delivered with shipping caps that are meant to protect the mating joint threads. Do NOT remove shipping caps until the pipe is to be installed and joints are to be secured. Failure to do so could result in damage to the mating threads.
NOTE:Do NOT reuse the fuel feed intermediate pipe (2). If the 2 fuel feed intermediate pipe nuts (1) are loosened or the fuel feed intermediate pipes are removed, the fuel feed intermediate pipes MUST be replaced.
Fuel Feed Intermediate Pipe Nut (1) @ Fuel Feed Intermediate Pipe (2) - Loosen until disengaged [ 2x ]
- Fuel Feed Intermediate Pipe (2) - Remove and DISCARD
- NOTE:
Do NOT reuse the fuel feed intermediate pipe (3). If the 2 fuel feed intermediate pipe nuts (1) are loosened or the fuel feed intermediate pipes are removed, the fuel feed intermediate pipes MUST be replaced.
Fuel Feed Intermediate Pipe Nut (1) - Loosen until disengaged [ 2x ]
- Fuel Feed Pipe Bolt (2) - Remove
- Fuel Feed Intermediate Pipe (3) - Remove and DISCARD
- Disconnect and reposition the fuel pump and fuel injector wiring harness as necessary.
- 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 Bolt (1) - Remove [ 2x ]
- Fuel Pump Cover (2) - Remove
- Fuel Pump Bolt Retainer (3) - Remove [ 2x ]
- Fuel Pump (4) - Remove
- Fuel Pump Bracket Gasket (5) - Remove and DISCARD
- Front Wheelhouse Liner- Left Side and Right Side - Remove - Front Wheelhouse Liner Replacement
- Engine Oil and Oil Filter - Remove and DISCARD - Engine Oil and Oil Filter Replacement
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.
Front Bumper Fascia Extension Bolt (2) - Remove [ 4x ]
- Front Bumper Fascia Extension Bolt @ Skid Shield (3) - Remove [ 2x ]
- Remove wiring harness retainers as necessary.
- Pull the front bumper fascia extension (4) rearward and down.
Underbody Skid Shield Bolt (1) - Remove [ 2x ]
- Underbody Skid Shield (2) - Remove
- WARNING:
Avoid contact with HOT components. Wear safety glasses and protective gloves to avoid personal injury.
CAUTION:Refer to Heated Oxygen and Oxygen Sensor Caution .
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 heated oxygen sensor (1).
- The heated oxygen sensor (1) MAY be difficult to remove when the engine temperature is less than 48°C (120°F).
Disconnect the heated oxygen sensor electrical connector.
- Using a suitable tool, remove the heated oxygen sensor (1).
Exhaust Heat Shield Bolt- Left Side (1) - Remove
- Exhaust Front Pipe Heat Shield- Left Side (2) - Remove
Exhaust Heat Shield Bolt- Right Side (1) - Remove
- Exhaust Front Pipe Heat Shield- Right Side (2) - Remove
- CAUTION:
Refer to Heated Oxygen and Oxygen Sensor Caution .
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 oxygen sensor (1).
- The heated oxygen sensor (1) MAY be difficult to remove when the engine temperature is less than 48°C (120°F).
Disconnect the heated oxygen sensor electrical connector.
- Using a suitable tool, remove the heated oxygen sensor (1).
- WARNING:
In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.
Exhaust Front Pipe Nut- Left Side (1) - Remove [ 3x ]
- WARNING:
In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.
Exhaust Front Pipe Nut- Right Side (1) - Remove [ 3x ]
Exhaust System Seal (1) - Remove and DISCARD
Exhaust System Seal (1) - Remove and DISCARD
- The steering column
- The intermediate shaft(s)
- The steering gear
- Secure the steering wheel so it will not turn when the upper intermediate steering shaft and steering column are disconnected.
Mid Intermediate Steering Shaft Bolt (1) - Remove
Upper Intermediate Steering Shaft (1) @ Intermediate Steering Shaft - Separate
- NOTE:
Pull only on the spark plug wire boot to remove the spark plug wire (1).
Twist the 4 spark plug wire boots a 1/2 turn and remove the spark plug wires (1) from the gas engine ignition spark plugs (2).
Remove the 3 left side exhaust manifold heat shield bolts (1) through the wheel opening.
Exhaust Manifold Heat Shield- Left Side (1) - Remove
Exhaust Manifold Bolt- Left Side (1) - Remove and DISCARD [ 5x ]
Exhaust Manifold- Left Side (1) - Remove
- Exhaust Manifold Gasket- Left Side (2) - Remove and DISCARD
Exhaust Manifold Heat Shield Bolt- Right Side (1) - Remove [ 3x ]
- NOTE:
Pull only on the spark plug wire boot to remove the spark plug wire (1).
Twist the 4 spark plug wire boots 1/2 turn and remove the 4 spark plug wires (1) from the 4 gas engine ignition spark plugs (2).
Remove the right exhaust manifold heat shield (1) through the wheel opening.
Exhaust Manifold Bolt- Right Side (1) - Remove and DISCARD [ 5x ]
Remove the right side exhaust manifold (1) through the wheel opening.
- Exhaust Manifold Gasket- Right Side (2) - Remove and DISCARD
Valve Rocker Arm Cover Bolt- Left Side (1) - Loosen until disengaged [ 9x ]
- Valve Rocker Arm Cover- Left Side (2) - Remove
Valve Rocker Arm Cover Gasket- Left Side (2) @ Valve Rocker Arm Cover (1) - Remove and DISCARD
- NOTE:
- Only replace the valve rocker arms (1) and valve push rods as required.
- The rocker arm pivot support bolts are not serviced separately.
- Place the valve rocker arms (1) and valve push rods in a rack so they can be installed in the same location from which they were removed.
Valve Rocker Arm Pivot Support Bolt (2) - Loosen until disengaged [ 8x ]
- Valve Rocker Arm (1) - Remove [ 8x ]
Valve Push Rod- Left Side (1) - Remove [ 8x ]
Engine Wiring Harness Ground Bolt (1) - Remove
- Engine Wiring Harness (2) - Remove
- NOTE:
The forward most fastener on the Left Side Cylinder Head is unique to all other cylinder head fasteners. It is shorter, has an internal hex drive and has a lower final tightening torque angle.
Cylinder Head Bolt M12 x 102 (1) - Remove and DISCARD
- Cylinder Head Bolt M12 x 134 (2) - Remove and DISCARD [ 9x ]
- CAUTION:
After removal, place the cylinder head on 2 wood blocks in order to prevent damage to the sealing surfaces.
Cylinder Head (2) - Remove
- Cylinder Head Gasket (1) - Remove and DISCARD
Heater Hose Clip Bracket Bolt (1) - Remove
- Heater Inlet and Outlet Hose Bracket (2) - Reposition
Retainer Clip (1) @ Cylinder Head - Right Side (2) - Remove
Valve Rocker Arm Cover Bolt (1) - Loosen until disengaged [ 10x ]
- Valve Rocker Arm Cover- Right Side (2) - Remove
Valve Rocker Arm Cover Gasket- Right Side (2) @ Valve Rocker Arm Cover (1) - Remove and DISCARD
- NOTE:
- Only replace the valve rocker arms (1) and valve push rods as required.
- The rocker arm pivot support bolts are not serviced separately.
- Place the valve rocker arms (1) and valve push rods in a rack so they can be installed in the same location from which they were removed.
Valve Rocker Arm Pivot Support Bolt (1) - Loosen until disengaged [ 8x ]
- Valve Rocker Arm (2) - Remove [ 8x ]
Valve Push Rod- Right Side (1) - Remove [ 8x ]
- NOTE:
Some components not shown for graphic clarity.
Engine Wiring Harness Ground Bolt (1) - Remove
- Engine Wiring Harness (2) - Reposition
Cylinder Head Bolt (1) - Remove and DISCARD [ 10x ]
- CAUTION:
After removal, place the cylinder head on 2 wood blocks in order to prevent damage to the sealing surfaces.
Cylinder Head (1) - Remove
- Cylinder Head Gasket (2) - Remove and DISCARD
Engine Block Valley Cover Bolt (2) - Loosen until disengaged [ 9x ]
- Engine Block Valley Cover (1) - Remove
Engine Block Valley Cover Gasket (2) @ Engine Block Valley Cover (1) - Remove and DISCARD
Wiring Harness Connector Seal (1) @ Valve Rocker Arm Oil Control Valve Harness (2) - Remove and DISCARD
Valve Lifter Follower Guide Bolt (1) - Remove
- Valve Lifter Follower Guide (2) - Remove
- Valve Lifter Follower (3) - Remove
- NOTE:
- Organize and mark the valve lifters (3), valve lifter guides (2), so they can be installed to their original location.
- Only replace the valve lifters (3) and valve lifter guides (2) as required.
Valve Lifter Guide Bolt- Left Side (1) - Remove (2)
- Remove the valve lifter guide (2) and the valve lifters (3) as an assembly.
Valve Lifter- Left Side (1) @ Valve Lifter Guide (2) - Remove
- NOTE:
- Organize and mark the valve lifters (3), valve lifter guides (2), so they can be installed to their original location.
- Only replace the valve lifters and valve lifter guides as required.
Valve Lifter Guide Bolt- Right Side (3) - Remove (2)
- Remove the valve lifter guide (2) and the valve lifters (1) as an assembly.
Valve Lifter- Right Side (1) @ Valve Lifter Guide (2) - 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 (1) - 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 (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
Electronic Suspension Rear Vertical Accelerometer Bolt (2) - Remove
- Electronic Suspension Wheel Front Vertical Accelerometer- Right Side (3) - Reposition
Steering Linkage Outer Tie Rod Nut (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 the CH-43631 Ball Joint Separator (1), remove the steering linkage outer tie rod from the steering knuckle.
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.
- 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.
Remove the front wheel drive half shaft (1) from the front axle.
- 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
- NOTE:
Only the left front wheel is equipped with the front disc brake pad wear sensor.
Front Disc Brake Pad Wear Sensor (1) @ Front Brake Caliper - 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
Electronic Suspension Rear Vertical Accelerometer Bolt (2) - Remove
- Electronic Suspension Wheel Front Vertical Accelerometer- Left Side (3) - Reposition
Steering Linkage Outer Tie Rod Nut (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 the CH-43631 Ball Joint Separator (1), remove the steering linkage outer tie rod from the steering knuckle.
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.
- 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.
Remove the front wheel drive half shaft (1) from the front axle.
- 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
Disconnect the electrical connector for the electronic suspension wheel front vertical accelerometer (1) and the front air shock harness electrical connector (2).
Unclip and reposition the chassis wiring harness bracket (1) away from the frame shock tower.
Disconnect the air line nut (1) and position the air line aside.
Front Shock Absorber Nut (1) - Remove [ 3x ]
Front Shock Absorber Bolt (1) - Remove [ 2x ]
Front Shock Absorber (1) - Remove
- NOTE:
Support the front stabilizer shaft.
Front Stabilizer Shaft Bolt (1) - Remove [ 4x ]
- 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.
- NOTE:
Some components not shown for graphic clarity.
Electrical Connector @ Heater Coolant Pump (2) - Disconnect
- 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
- Torque 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
- Torque Converter Cover- Right Side (2) - Remove
Position the EN-42386 Flywheel Holding Tool (1) into place.
- Install the M10-1.5 x 120 mm (3) and the M10-1.5 x 45 mm (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
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).
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).
Engine Front Cover Bolt (1, 3) - Remove [ 10x ]
- Engine Front Cover (2) - Remove
Oil Pump Bolt (1) - Remove [ 4x ]
Oil Pump (1) - Remove
Inspect the seal (3) of the timing chain tensioner for damage and wear. If damaged or worn replace the timing chain tensioner.
- 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
- WARNING:
Refer to Camshaft Position Actuator Removal and Installation Warning .
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.
- 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
Camshaft Retainer Bolt (2) - Remove [ 4x ]
- Camshaft Retainer (1) - Remove
Camshaft (1) - Remove
- Using the appropriate tool, clean and prepare the applicable sealing surface.
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 became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil.
Note the installed position of the valve lifter guides (2). The notched area of the valve lifter guides (2) align with the locating tab on the engine block.
Note the installed position of the valve lifter guides (2). The notched area of the valve lifter guides (2) align with the locating tab on the engine block.
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.
Components removed in graphic to better illustrate service parts.