Removal Procedure

Relieve the fuel system pressure. Fuel Pressure Relief
Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
Drain the cooling system. Cooling System Draining and Filling (GE 47716)
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Oil Filler Cap - Remove
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Intake Manifold Cover (1) - Remove
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NOTE:
To avoid small parts like bolts or retainers fallen into the engine, install the Oil Filler Cap.

Oil Filler Cap (1) - Install
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Positive Crankcase Ventilation Fresh Air Tube (1) @ Air Cleaner Outlet Duct - Disconnect - Plastic Collar Quick Connect Fitting Service
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Turbocharger Outlet Duct Front Clamp (1) - Loosen
Air Cleaner Outlet Duct Clamp (5) - Loosen
Air Cleaner Outlet Duct Bolt (2) - Remove [2x]
Air Cleaner Outlet Duct Nut (3) - Remove
Air Cleaner Outlet Duct (4) - Remove
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Charge Air Cooler Bolt (1) - Remove [4x]
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Charge Air Cooler Outlet Air Hose Clamp (1) - Loosen [2x]
Charge Air Cooler Coolant Hose Retainer (2) - Disengage [2x]
Charge Air Cooler Coolant Hose (3) - Reposition [2x]
Charge Air Cooler Inlet Air Hose Clamp (4) - Loosen
Disconnect the electrical connector. (5)
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Charge Air Cooler (1) - Remove
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Charge Air Cooler Bracket Bolt (1) - Remove [4x]
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Charge Air Cooler Bracket (1) - Remove
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Charge Air Cooler Inlet Air Hose Clamp Nut (1) - Remove
Charge Air Cooler Coolant Hose (2) - Reposition
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Release the hose retainers (1) as necessary.
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Release the hose retainers (1) as necessary.
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Intake Manifold Cover Bolt (1) - Remove [3x]
Oil Level Indicator Tube Bracket Bolt (2) - Remove
Oil Level Indicator - Reposition
Disconnect the electrical connectors and release the wiring harness retainers as necessary.
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Intake Manifold Cover (1) - Remove
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Intake Manifold Bolt (1) - Remove [5x]
Intake Manifold (2) - Remove
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Intake Manifold Gasket @ Intake Manifold (1) - Remove and DISCARD
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Tie Strap (2) - Remove and DISCARD
Disconnect the electrical connector.
CAUTION:
Refer to Fuel and Evaporative Emission Hose / Pipe Connection Cleaning Caution .

CAUTION:
To tighten or loosen the fuel injection fuel rail fuel pressure sensor, apply force ONLY to the attached hexagon. Applying force to the plastic housing of the sensor may damage the sensor.

NOTE:
Some fuel may leak from the fuel rail pressure sensor orifice after the sensor is removed. Dry the area around this orifice after the removal of the sensor using a lint free cloth and inspect the fuel rail pressure sensor sealing surface. The surface should be free of fuel, debris, and burrs.
Fuel Rail Pressure Sensor (1) - Remove