Removal Procedure
- Remove the negative battery cable from the battery. 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
- 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
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 (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.
- 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
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
- 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
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
- 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
- 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
- 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
- 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
- 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
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).
Disconnect Oil Pump Flow Control Solenoid Valve Wire connector (3) from the Oil Pump Flow Control Solenoid Valve (4).
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 seal.
Using a suitable tool, remove the timing chain tensioner seal (1).
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.
If the engine front cover is reused, the crankshaft front oil seal must be replaced.