REMOVAL
ENGINE - 2.8L DIESEL
NOTE: The export manual transmissions must be removed from the vehicle before removing the engine.
1. Disconnect negative battery cable.
2. Disconnect under hood lamp from the hood assembly.
3. Drain cooling system (Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE) .
4. Remove engine cover (Refer to 9 - ENGINE - REMOVAL) .
5. Remove air cleaner assembly from the engine bay .
6. Recover refrigerant from A/C system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE) .
7. Disconnect high side refrigerant line from the upper radiator support bracket.
8. Remove upper radiator support bracket retaining bolts and remove the support bracket.
9. Remove front grille and head lamp panel.
10. Remove from fascia.
11. Remove high side refrigerant line retaining nut and remove the line from the condenser assembly. Position the line out of the way.
12. Remove cooling fan and fan drive viscous clutch assembly.
13. Remove fan shroud retaining bolts and remove fan assembly and shroud together.
14. Disconnect charge air cooler hoses from charge air cooler.
15. Disconnect engine coolant hoses from engine assembly.
16. Disconnect coolant reservoir hose from radiator.
17. Remove low side refrigerant line retaining nut and remove line from the condenser assembly. Position the line out of the way.
18. Remove condenser assembly retaining bolts and remove condenser from the vehicle.
19. Remove power steering cooler retaining bolts and unclip air deflectors from both sides of the radiator (cooling module) assembly.
20. Remove cooling module assembly.
21. Remove charge air cooler hose from the intake manifold.
22. Remove high side refrigerant line from A/C compressor and remove high side line from the engine bay.
23. Remove coolant reservoir retaining nuts and clips retaining electrical harness, position reservoir aside to allow access to remaining hoses.
24. Disconnect remaining hoses from coolant reservoir and remove reservoir.
25. Remove accessory drive belt from the engine (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL) .
26. Accessing bolts through the pump pulley, remove power steering pump retaining bolts and position pump aside with lines still attached.
27. Remove engine cover mounting bracket retaining bolts and remove the bracket from the top of the engine.
28. Disconnect heater core inlet and outlet hoses from the heater core.
29. Remove generator from engine (Refer to 8 - ELECTRICAL/CHARGING/GENERATOR - REMOVAL) . This will provide access to the wires beneath it.
30. Remove low side refrigerant line retaining nuts from accumulator and compressor and remove from engine bay.
31. Trace engine wiring and disconnect electrical connectors and tie straps one at a time until all wiring is disconnected from the engine assembly. When all the engine electrical harness is disconnected position the harness aside.
32. Remove coolant elbow retaining bolts from rear of the water pump.
33. Disconnect coolant hoses leading from the coolant elbow and remove coolant elbow from engine.
34. Remove oil cooler adapter.
35. Raise and support the vehicle.
36. Remove oil filter and adaptor assembly.
37. Remove starter motor from engine (Refer to 8 - ELECTRICAL/STARTING/STARTER MOTOR - REMOVAL) .
38. Remove chassis ground wire above starter mounting location on the engine block.
39. Support the transmission with a jackstand.
40. Remove the flex plate access cover.
41. Remove the flex plate fasteners.
42. Remove transmission cross member fasteners.
43. Lower the transmission.
44. Remove the upper transmission to engine fasteners.
45. Raise the transmission.
46. Install the transmission cross member fasteners.
47. Remove the transmission jack.
48. Remove exhaust inlet pipe retaining bolts and disconnect exhaust pipe from turbocharger.
49. Remove transmission to engine retaining bolts.
50. Separate transmission cooler line(s) from retainer.
51. Connect a suitable lifting device to engine assembly.
52. Remove right side engine mount retaining nut.
53. Lower vehicle.
54. Remove left side engine mount retaining nut.
55. Remove exhaust manifold rear heat shield.
56. Disconnect the fuel supply and return lines.
57. Remove crankshaft sensor heat shield.
58. Disconnect crankshaft position sensor, located on the right rear of the engine.
59. Remove the oil separator from the cylinder head cover/intake manifold.
60. Disconnect oil pressure sensor. Make certain everything is disconnected from the engine assembly.
61. Place a floor jack under the transmission to support the transmission.
62. With engine and transmission supported by a lifting device separate the engine from the transmission.
63. Lift the engine assembly out of the engine bay.
ENGINE COVER
1. Remove oil fill cap.
2. Carefully lift engine cover (2) from corners to remove from mounting bracket (1).