Engine Mount Replacement - Left Side (4WD)

Single Use Fasteners and Components Engine Mount Engine Side Bolt [2x] Engine Mount Frame Side Bolt [3x] Engine Oil Cooler Gasket - Large Engine Oil Cooler Gasket - Small Transmission Fluid Cooler Seal Transmission Fluid Cooler Pipe Seal [2x] Turbocharger Coolant Feed and Return Pipe Gasket Special Tools EN-36857 Engine Lift Bracket EN-51768 Engine Support Fixture Adaptor Bolt - M8 Equivalent regional tools: Special Tools

Caution

Broken engine mountings can cause misalignment of certain drive-train components. Misalignment of drive-train components causes eventual destruction of the drive-train components. If one engine mount breaks, the rest of the engine mounts will have increased stress put on them. This could cause the rest of the engine mounts to break. Removal Procedure

1. Oil Filler Cap » Remove

Engine Mount Replacement - Left Side (4WD) — figure 1

2. Intake Manifold Cover Bolt (1) » Remove
3. Intake Manifold Cover (2) » Remove
4. Install the oil filler cap after removal of the intake manifold cover to prevent debris from falling into the engine.

Engine Mount Replacement - Left Side (4WD) — figure 2

Note

Some components not shown for graphic clarity.

5. Engine Wiring Harness Bracket Nut (1) » Remove [2x]
6. Engine Wiring Harness Bracket Bolt (2) » Remove
7. Reposition the engine wiring harness channel (3) away from the front of the engine.

Engine Mount Replacement - Left Side (4WD) — figure 3

8. Remove the fuel injector wiring harness connector (1) from the engine coolant air bleed bracket.
9. Drain the cooling system. Cooling System Draining and Filling
10. Drain the engine oil. Engine Oil and Oil Filter Replacement

Engine Mount Replacement - Left Side (4WD) — figure 4

11. Remove the right upper coolant air bleed hose bolt (1) and position the upper air bleed hose aside.

Engine Mount Replacement - Left Side (4WD) — figure 5

Note

It is not necessary to remove both gaskets.

12. Turbocharger Coolant Feed and Return Pipe Gasket - Right Side Upper (1) » Remove and DISCARD

Engine Mount Replacement - Left Side (4WD) — figure 6

13. { If equipped } Engine Wiring Harness Ground Bolt (1) » Remove
14. { If equipped } Ground Cable (2) » Remove

Engine Mount Replacement - Left Side (4WD) — figure 7

Note

Air bleed hose assembly removed for clarity.

15. Install the EN-36857 Engine Lift Bracket (1) to the front left side of the cylinder head using EN-51768 Engine Support Fixture Adaptor Bolt - M8 (2).
16. Front Wheelhouse Liner - Left Side » Remove — Front Wheelhouse Liner Replacement

Engine Mount Replacement - Left Side (4WD) — figure 8

17. Automatic Transmission Fluid Cooling Heat Exchanger Outlet Hose Clamp (1) » Disengage [2x] — Hose Clamp Replacement Guidelines - Spring Type
18. Automatic Transmission Fluid Cooling Heat Exchanger Outlet Hose (2) » Remove

Engine Mount Replacement - Left Side (4WD) — figure 9

19. Automatic Transmission Fluid Cooling Heat Exchanger Inlet Hose Clamp (1) » Disengage [2x] — Hose Clamp Replacement Guidelines - Spring Type
20. Automatic Transmission Fluid Cooling Heat Exchanger Inlet Hose (2) » Remove

Engine Mount Replacement - Left Side (4WD) — figure 10

21. Mark a reference point between the front axle propeller shaft (1) and the front differential drive pinion gear yoke.
22. Front Axle Propeller Shaft Bolt (2) » Remove [6x]
23. Front Axle Propeller Shaft Washer (3) » Remove [3x]

Engine Mount Replacement - Left Side (4WD) — figure 11

24. Front Axle Propeller Shaft (1) » Reposition away

Engine Mount Replacement - Left Side (4WD) — figure 12

25. Fuel Heater Inlet and Outlet Bolt (3) » Remove

Engine Mount Replacement - Left Side (4WD) — figure 13

26. Transmission Fluid Cooler Pipe Nut (1) » Remove [2x]
27. Transmission Fluid Cooler Pipe Bolt (2) » Remove

Engine Mount Replacement - Left Side (4WD) — figure 14

Note

Some components not shown for graphic clarity.

28. Transmission Fluid Cooler Inlet and Outlet Pipe (1) » Remove
29. Transmission Fluid Cooler Seal (2) » Remove and DISCARD
30. Transmission Fluid Cooler Pipe Seal (3) » Remove and DISCARD [2x]
31. Cap the fittings and plug the holes when removing the transmission fluid cooler pipes.

Engine Mount Replacement - Left Side (4WD) — figure 15

32. Automatic Transmission Fluid Cooling Exchanger Nut (2) » Remove
33. Automatic Transmission Fluid Cooling Exchanger Bolt (1) » Remove [2x]

Engine Mount Replacement - Left Side (4WD) — figure 16

34. Automatic Transmission Fluid Cooling Exchanger (1) » Remove

Engine Mount Replacement - Left Side (4WD) — figure 17

35. Thermostat Bypass Hose Clamp (1) » Disengage [2x] — Hose Clamp Replacement Guidelines

• Spring Type

36. Engine Oil Cooler Coolant Inlet Hose Clamp (2) » Disengage — Hose Clamp Replacement Guidelines - Spring Type
37. Engine Oil Cooler Coolant Outlet Hose (3) @ Engine Oil Cooler » Remove
38. Automatic Transmission Fluid Cooling Heat Exchanger Outlet Hose (4) @ Engine Oil Cooler » Remove
39. Engine Oil Cooler Coolant Inlet Hose (5) @ Engine Oil Cooler » Remove

Engine Mount Replacement - Left Side (4WD) — figure 18

40. Engine Oil Cooler Bolt (1) » Remove [5x]

Engine Mount Replacement - Left Side (4WD) — figure 19

41. Engine Oil Cooler » (1) Remove
42. Engine Oil Cooler Gasket (2) » Remove and DISCARD
43. Engine Oil Cooler Gasket (3) » Remove and DISCARD
44. Detach engine coolant heater cord retainers and position aside as necessary.

Engine Mount Replacement - Left Side (4WD) — figure 20

45. Working through the wheelhouse opening Remove and DISCARD the 3 engine mount frame side bolts (1).

Caution

When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the crankshaft pulley. Lifting the engine in an unapproved manner may cause component damage.

Note

When raising the engine only raise enough to separate the engine mount from the engine mount bracket. Raising any further will require removal of the fan shroud or the exhaust pipe.

46. Raise the engine with a suitable lifting device to remove the engine mount.

Engine Mount Replacement - Left Side (4WD) — figure 21

47. Remove and DISCARD the 2 engine mount engine side bolts (1).
48. If equipped, disconnect electrical connector at the rear of engine mount.

Engine Mount Replacement - Left Side (4WD) — figure 22

49. Engine Mount (1) » Remove Cleaning and Inspection Procedure - Conditional

Note

The following cleaning and inspection and/or overhaul steps are ONLY to be performed as determined necessary based on the condition of the part being removed with the intention of reinstallation. The labor time to perform any of these steps is not included in the base labor time and if required would need to be documented and submitted as Other Labor Hours for warranty claim reimbursement. A description of the repairs performed must be documented in the technician correction comments.

Engine Mount Replacement - Left Side (4WD) — figure 23

1. Clean the engine oil cooler (1,2).

2. Inspect the engine oil cooler (1,2).

3. Replace the engine oil cooler (1,2) if any damage is found. Installation Procedure

4. Engine Mount (1) » Install

5. If equipped, connect electrical connector at the rear of engine mount.

6. If a NEW threaded component is being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded component is reused, prepare the threaded component using the following steps: 3.1. Remove any loose cured adhesive from the external threads of the component using a lint free cloth. 3.2. Thread the cleaned component into the internal mating threads and remove to loosen trapped cured adhesive. 3.3. Apply thread locking adhesive to the external threads of the component. Adhesives, Fluids, Lubricants, and Sealers 3.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

Caution

Refer to Fastener Caution.

4. Install and tighten the 2 NEW engine mount engine side bolts (1). Fastener Specifications

5. Lower the engine.

6. If a NEW threaded component is being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded component is reused, prepare the threaded component using the following steps: 6.1. Remove any loose cured adhesive from the external threads of the component using a lint free cloth. 6.2. Thread the cleaned component into the internal mating threads and remove to loosen trapped cured adhesive. 6.3. Apply thread locking adhesive to the external threads of the component. Adhesives, Fluids, Lubricants, and Sealers 6.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

7. Install and tighten the 3 NEW engine mount frame side bolts (1). Fastener Specifications

8. Remove the lifting device from the EN-36857 Engine Lift Bracket.

9. Position and attach engine coolant heater cord retainers as necessary.

10. Engine Oil Cooler Gasket (3) » Install NEW

11. Engine Oil Cooler Gasket (2) » Install NEW

12. Engine Oil Cooler (1) » Install

13. Engine Oil Cooler Bolt (1) » Install and tighten [5x] — Fastener Specifications

14. Engine Oil Cooler Coolant Inlet Hose (5) @ Engine Oil Cooler » Install

15. Automatic Transmission Fluid Cooling Heat Exchanger Outlet Hose (4) @ Engine Oil Cooler » Install

16. Engine Oil Cooler Coolant Outlet Hose (3) @ Engine Oil Cooler » Install

17. Engine Oil Cooler Coolant Inlet Hose Clamp (2) » Engage — Hose Clamp Replacement Guidelines - Spring Type

18. Thermostat Bypass Hose Clamp (1) » Engage [2x] — Hose Clamp Replacement Guidelines - Spring Type

19. Automatic Transmission Fluid Cooling Exchanger (1) » Install

20. Automatic Transmission Fluid Cooling Exchanger Bolt (1) » Install and tighten [2x] — Fastener Specifications

21. Automatic Transmission Fluid Cooling Exchanger Nut (2) » Install and tighten — Fastener Specifications

Note

Some components not shown for graphic clarity.

22. Remove the caps from the fittings and plugs from the holes before installing the transmission fluid cooler pipes.

23. Transmission Fluid Cooler Seal (2) » Install NEW

24. Transmission Fluid Cooler Pipe Seal (3) » Install NEW [2x]

25. Transmission Fluid Cooler Inlet and Outlet Pipe (1) » Install

26. Transmission Fluid Cooler Pipe Bolt (2) » Install and tighten — Fastener Specifications

27. Transmission Fluid Cooler Pipe Nut (1) » Install and tighten [2x] — Fastener Specifications

28. Fuel Heater Inlet and Outlet Bolt (3) » Install and tighten — Fastener Specifications

Engine Mount Replacement - Left Side (4WD) — figure 24

29. Front Axle Propeller Shaft (3) » Install

30. Align the reference marks made between the front axle propeller shaft (1) and the front differential drive pinion gear yoke.

31. Front Axle Propeller Shaft Washer (3) » Install [3x]

32. If a NEW threaded component is being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded component is reused, prepare the threaded component using the following steps: 32.1. Remove any loose cured adhesive from the external threads of the component using a lint free cloth. 32.2. Thread the cleaned component into the internal mating threads and remove to loosen trapped cured adhesive. 32.3. Apply thread locking adhesive to the external threads of the component. Adhesives, Fluids, Lubricants, and Sealers 32.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

33. Install the 6 front axle propeller shaft bolts (2) and tighten in a crisscross pattern. Fastener Specifications

34. Automatic Transmission Fluid Cooling Heat Exchanger Inlet Hose (2) » Install

35. Automatic Transmission Fluid Cooling Heat Exchanger Inlet Hose Clamp (1) » Engage [2x] — Hose Clamp Replacement Guidelines - Spring Type

36. Automatic Transmission Fluid Cooling Heat Exchanger Outlet Hose (2) » Install

37. Automatic Transmission Fluid Cooling Heat Exchanger Outlet Hose Clamp (1) » Engage [2x] — Hose Clamp Replacement Guidelines - Spring Type

38. Front Wheelhouse Liner » Install — Front Wheelhouse Liner Replacement

39. Remove the EN-36857 Engine Lift Bracket (1) from the front left side of the cylinder head using EN-51768 Engine Support Fixture Adaptor Bolt - M8 (2).

40. Turbocharger Coolant Feed and Return Pipe Gasket - Right Side Upper (1) » Install NEW

41. Install the right upper coolant air bleed hose bolt (1). Fastener Specifications

42. { If equipped } Ground Cable (2) » Install

43. { If equipped } Engine Wiring Harness Ground Bolt (1) » Install and tighten — Ground Repair

44. Install the fuel injector wiring harness connector (1) to the engine coolant air bleed bracket.

Note

Some components not shown for graphic clarity.

45. Position the engine wiring harness channel (3) to the front of the engine.

46. Engine Wiring Harness Bracket Bolt (2) » Install and tighten — Fastener Specifications

47. Engine Wiring Harness Bracket Nut (1) » Install and tighten [2x] — Fastener Specifications

48. Oil Filler Cap » Remove

49. Intake Manifold Cover (2) » Install

50. Intake Manifold Cover Bolt (1) » Install and tighten — Fastener Specifications

51. Oil Filler Cap » Install

52. Fill the cooling system. Cooling System Draining and Filling

53. Fill the engine oil to the proper level with NEW engine oil. Engine Oil and Oil Filter Replacement

54. Check the transmission fluid level. Transmission Fluid Level and Condition Check