KJ CRD Engine Mount Replacement

1. Complete this procedure with a cold engine. 2. Remove the CAC hose connection at the turbocharger compressor outlet using a flathead screwdriver or 8mm nut driver to loosen the screw clamp. Then move the CAC hose out of the way.

Green Diesel Engineering P.O. Box 930639 Wixom, MI 48393

3. Remove the clean air duct by loosening the screw clamp at the air box and at the inlet to the turbo compressor. Also remove the hose that goes to the CCV outlet on the engine. Remove clean air assembly and set aside.

Green Diesel Engineering P.O. Box 930639 Wixom, MI 48393

Green Diesel Engineering P.O. Box 930639 Wixom, MI 48393

4. Now you have access to the top engine mount retention nut. Remove this using an 18mm socket, with a universal joint and 24 of extension.

Green Diesel Engineering P.O. Box 930639 Wixom, MI 48393

5. Under the vehicle it is necessary to remove the skid plate. This is held in place with (4) 16mm bolts. The front two must be removed and the rear two can be loosened a couple turns as the skid plate is slotted in the rear. Then the skid plate can be dropped down a couple inches and skid forward to remove. 6. Locate the 18mm nut on the bottom side of the engine mount, access from under the vehicle. Remove this nut.

Green Diesel Engineering P.O. Box 930639 Wixom, MI 48393

7. Use a jack with a short 2x4 wood piece and locate it on the oil sump toward the passenger side. Lift the engine as high as it will go making sure the jack is not catching on the axle or cross member.

Green Diesel Engineering P.O. Box 930639 Wixom, MI 48393

8. Now the engine mount can be pushed up enough from underneath the vehicle to free it from the engine mount bracket. The mount can slide down next to the exhaust pipe and engine block to be removed. You may need to push the transmission cooler lines outboard a bit.

Green Diesel Engineering P.O. Box 930639 Wixom, MI 48393

Green Diesel Engineering P.O. Box 930639 Wixom, MI 48393

9. The engine mount heat shield needs to be removed and installed on the new mount prior to reassembly. 10.Reinstall everything in the reverse order and torque the engine mounts as tight as possible or 82 ft*lb as specified in the 2005 KJ service manual.

Green Diesel Engineering P.O. Box 930639 Wixom, MI 48393