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)
Oil Filler Cap - Remove
Intake Manifold Cover (1) - Remove
- NOTE:
To avoid small parts like bolts or retainers fallen into the engine, install the Oil Filler Cap.
Oil Filler Cap (1) - Install
Positive Crankcase Ventilation Fresh Air Tube (1) @ Air Cleaner Outlet Duct - Disconnect - Plastic Collar Quick Connect Fitting Service
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
Charge Air Cooler Bolt (1) - Remove [4x]
Charge Air Cooler Outlet Air Hose Clamp (1) - Loosen
- 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)
Charge Air Cooler (1) - Remove
- WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise canceling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.
Fuel Pump Insulator (1) - Remove
Radiator Surge Tank Outlet Pipe Nut (1) - Remove
- Radiator Surge Tank Air Separator Hose Bracket (2) - Reposition
Fuel Feed Intermediate Pipe Nut (1) @ Fuel Feed Intermediate Pipe - Loosen [2x]
- Fuel Injection Fuel Feed Pipe Bracket Bolt (4) - Remove
- Retainer (3) - Disengage
- Fuel Feed Intermediate Pipe (2) - Remove and DISCARD
Charge Air Cooler Bracket Bolt (1) - Remove [4x]
Charge Air Cooler Bracket (1) - Remove
Charge Air Cooler Inlet Air Hose Clamp Nut (1) - Remove
- Charge Air Cooler Coolant Hose (2) - Reposition
Release the hose retainers (1) as necessary.
Release the hose retainers (1) as necessary.
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.
Intake Manifold Cover (1) - Remove
Intake Manifold Bolt (1) - Remove [5x]
- Intake Manifold (2) - Remove
Intake Manifold Gasket @ Intake Manifold (1) - Remove and DISCARD
- WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise canceling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.
Fuel Injection Fuel Rail Noise Shield (1) - Remove
Disconnect the electrical connectors and release the wiring harness retainers as necessary. (2, 3)
Fuel Injection Fuel Rail Bolt (1) - Remove [4x]
- NOTE:
- In some cases, the fuel injectors may be difficult to remove because of heavy carbon build-up or other factors. DO NOT use excessive force with the removal tool. If injectors are difficult to remove, apply solvent to the base of the injector bores, and allow adequate soaking time, to loosen the fuel injectors.
- Pull the direct fuel injection fuel rail and injectors as an assembly.
- To prevent material from entering the combustions chambers make sure the area around each injector is clean and free of debris before the injectors are removed from the injector bores.
Install EN-49248 Injector Rail Assembly Remover (1).
- Install the remover into the direct fuel injection fuel rail fastener bores.
- Remove by turning each section of the EN-49248 Injector Rail Assembly Remover (1) an even amount to pull the direct fuel injection fuel rail and injectors (2) out evenly.
- CAUTION:
- Remove the fuel rail assembly carefully in order to prevent damage to the injector electrical connector terminals and the injector spray tips. Support the fuel rail after the fuel rail is removed in order to avoid damaging the fuel rail components.
- Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering open pipes and passages.
Simultaneously lift both ends of the direct fuel injection fuel rail (1) and remove the direct fuel injection fuel rail from the cylinder head.
Disconnect the electrical connectors and release the wiring harness retainers as necessary.
- Fuel Injector Retainer (1) - Remove and DISCARD
- Fuel Injector (2) - Remove
Remove and DISCARD the remaining fuel injector nozzle housing seals (1).