There are 8 steps needed to safely take out a truck engine. It can be an intimidating task, and for someone who hasn't done this before, the process can be time consuming. If not done correctly, it can be costly and unsafe. But by having the proper tools, and by following the correct procedure, you can remove a truck engine safely and properly. As there are many different types of trucks on the road, each will have some parts or assemblies that others do not. It is recommended to have a manual for the truck that you will be working on to help answer any questions you have.
As there will be many bolts that will be removed in this process, it is highly recommended to label and organize the bolts as they are removed so they don't get lost or misused. If you do not have a lot of experience in this type of work, it is recommended to label all of the hoses as they are removed from the engine. You may even want to take pictures of each step of the process in case there are any questions later when reinstalling the engine
Step 1 - Drain Fluids
Drain the radiator fluid and remove all the hoses attached to the engine. Use a 5 gallon bucket to remove the fluid. You may want to wear rubber gloves to protect your arms and hands from the radiator fluid.
Step 2 - Fan and Radiator
Remove the fan and the radiator. The truck manual may come in handy for any technical issues that may come up.
Step 3 - Loosen Power Steering Pump
You will need a wrench to loosen the pump. Be sure to just loosen the pump to the point that you can move it out of your way, but do not completely disconnect it.
Step 4 - Loosen Electrical Wires
You do not need to remove the spark plugs.
Step 5 - Exhaust Manifold and Engine Block
With a wrench, loosen the exhaust manifold and take the bolts off where the transmission attaches to the engine block.
Step 6 - Starter and Exhaust Pipe
At this point, you will need to raise the truck up with a truck jack. Make sure the jack is certified to hold the weight of the truck. Place jack-stands under truck frame for your safety. Carefully slide underneath the truck and remove the starter and exhaust pipe connectors. Lower the truck and remove the jack.
Step 7 - Transmission and Engine Mount Connections
With a wrench, remove all of the transmission connections and the engine mount connections.
Step 8 - Remove Engine
Wrap a heavy chain around the engine from both sides. If you do not have an engine hoist to raise the engine, have someone assist you in lifting the engine block out of the truck. DO NOT ATTEMPT TO REMOVE THE ENGINE ON YOUR OWN. Also, be sure to keep the front part of the engine higher than the back part.
Remember, it is very important that you have the proper tools and support when removing a truck engine. If there are any doubts about the process, consult a professional mechanic accustomed to this type of work.