Contents: Removal ⇩ Installation ⇩
Removal
1. Disconnect the ground cable from the battery. For more information, refer to Specification.
2. Remove the crankcase ventilation oil separator. For more information, refer to Engine Crankcase Ventilation Oil Separator (10/17/04)
3. Remove the battery. For more information, refer to Battery (86.15.01)
4.
NOTE: Right-hand drive vehicle shown. On left-hand drive vehicles, perform the steps in reverse order.
Disconnect the three engine wiring harness electrical connectors.
5. Remove the engine wiring harness from the bulkhead.
6.
NOTE: Left side shown, right side is done in the same way.
Disconnect the electrical connectors from the knock sensor (KS).
7.
NOTE: Left side shown, right side is done in the same way.
Disconnect the fuel injector electrical connectors.
8.
NOTE: Left side shown, right side is done in the same way.
Remove the engine wiring harness from the fuel rail.
9. Disconnect the right EGR valve electrical connector.
10. Remove the engine wiring harness from the timing belt cover.
11. Disconnect the engine coolant temperature (ECT) sensor electrical connector. Remove the engine wiring harness from the engine lift.
12. Remove the engine wiring harness from the timing belt cover.
13. Remove the left EGR valve. For more information, please refer to the Left Exhaust Gas Recirculation Valve (EGR) - The vehicle package does not include: Diesel engine fuel filter (17.45.16)
14. Disconnect the camshaft position (CMP) sensor electrical connector.
15. Remove the power steering pump. For more information, refer to Power Steering Pump -2.7L Diesel, VIN Range: SALLA000304->END OF 06MY (57.20.14)
16. Remove the power steering pump support bracket. Remove the 3 mounting bolts.
17. Disconnect the air conditioning compressor electrical connector.
18. Disconnect the turbocharger electrical connector.
19. Disconnect the crankshaft position sensor (CKP) electrical connector.
20. Remove the engine protection screen. For more information, refer to Engine Protection (76.10.50)
21. Disconnect the electrical connector of the engine oil temperature sensor. Remove the engine wiring harness from the oil pan.
22. Disconnect the starter solenoid electrical connector.
23. Disconnect the generator electrical connector.
24. Remove the engine wiring harness.
Installation
1. Install the engine wiring harness.
2. Connect the generator electrical connector.
3. Connect the starter solenoid electrical connector. Tighten to 7 Nm.
4. Connect the electrical connector of the engine oil temperature sensor. Connect the engine wiring harness to the oil pan.
5. Install the engine protection screen. For more information, refer to Engine Protection (76.10.50)
6. Connect the crankshaft position (CKP) sensor electrical connector.
7. Connect the turbocharger electrical connector.
8. Connect the air conditioning compressor electrical connector.
9. Install the power steering pump support bracket. Tighten the lock bolts. (tightening torque 25 Nm).
10. Install the power steering pump. For more information, refer to Power Steering Pump -2.7L Diesel, VIN Range: SALLA000304->END OF 06MY (57.20.14)
11. Connect the CMP sensor electrical connector.
12. Install the left EGR valve. For more information, please refer to Cool Exhaust Gas Recirculation Valve (EGR) - The vehicle package does not include: Diesel engine fuel filter (17.45.16)
13. Connect the engine wiring harness to the timing belt cover.
14. Connect the ECT sensor electrical connector. Attach the engine wiring harness to the engine lift.
15. Connect the engine wiring harness to the timing belt cover.
16. Connect the right EGR valve electrical connector.
17. Connect the engine wiring harness to the fuel rail.
18. Connect the fuel injector electrical connectors.
19. Connect the electrical connectors of the KS sensor.
20. Connect the engine wiring harness to the bulkhead.
21. Connect the three electrical connectors of the engine wiring harness.
22. Install the battery. For more information, refer to Battery (86.15.01)
23. Install the crankcase ventilation oil separator. For more information, refer to Crankcase Ventilation Oil Separator (10/17/04)
24. Connect the ground cable to the battery. For more information, refer to Specification.
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