5-101.bk Page 2 Friday, March 17, 2006 11:05 AM GENERAL 3. Using an appropriate filter wrench, remove the oil filters, fuel filters and coolant conditioner. Details of the engine removal procedure vary from one vehicle to another. This section provides general guidelines for removing the engine from the vehicle. 4. Loosen clamps that secure the air intake tube to the turbocharger and air filter. Remove the intake tube. 5. If vehicle is equipped with air conditioning: Before beginning engine removal, make sure all equipment is available for use and has been inspected for safety. a. Using A/C refrigerant recovery and recycling equipment, recover the A/C system refrigerant. b.
Disconnect the A/C compressor discharge hose at connection near the radiator support. Vehicle Preparation c. Disconnect the A/C line at the receiver/dryer. It is good practice to steam-clean the engine to remove road grime, grease and oil before starting work. Steam cleaning the engine and engine area allows more detailed inspection and improved workmanship. d. Locate and disengage the electrical connector from binary pressure switch on the receiver/dryer. e. Locate and disengage the electrical connector from the low-pressure cutout switch in the A/C refrigerant line. Care must be used to keep moisture from entering the air intake system.
If moisture does enter the system, make sure it is removed (dried out) before the engine is reinstalled. 6. Disconnect the upper radiator hose from the engine coolant outlet fitting. 7. Disconnect the lower radiator hose from the coolant inlet of the oil cooler assembly. 1. Position vehicle on a flat and level surface in an area with ample work space in and around the vehicle. Ensure that a suitable lifting device is available. 8. Remove the clamps that retain the coolant overflow tank. Remove tank. 9. Disconnect the chassis-mounted charge air cooler inlet hose at the cooler. 2. Apply the parking brake and block the vehicle wheels to prevent vehicle from moving.
Observe all safety precautions. 10. Disconnect the chassis-mounted charge air cooler outlet hose at the cooler. 11. Locate the engine coolant temperature sensor and disengage the electrical connector, if applicable. Remove sensor harness from the radiator support. 3. Disconnect the battery negative (ground) cable. 4. Drain the air tanks. 12. Remove fastener from the bracket that secures the radiator fan air clutch solenoid valve to the radiator support. Set the solenoid valve aside. Engine Removal 1. Remove the hood and position it away from the work area to prevent accidents or hood damage. Refer to Hood Removal procedures in the appropriate vehicle manual. 13.
Remove the retaining bolts from the radiator support rods at the radiator support. 14. Obtain a lifting device (chain fall or engine hoist) and support the radiator. 2. Place a suitable container beneath the engine and drain engine oil and coolant. Open the coolant drain valves in the block, if applicable. 15. Remove the retaining bolts from the radiator support mounts. 16. Remove the radiator from the vehicle using a lifting device and an assistant, if required. Page 3-2 200 ENGINE REMOVAL