Removal Procedure
- Relieve the fuel system pressure. Fuel Pressure Relief
- Drain the cooling system. Cooling System Draining and Filling (GE 47716) , or Cooling System Draining and Filling (Static)
- Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
{If equipped} Intake Manifold Cover Bolt (1) - Remove [2x]
- If equipped, lift up on the front of the intake manifold cover (2).
{If equipped} Intake Manifold Cover (1) @ Upper Intake Manifold Bracket (2) - Remove
Air Cleaner Outlet Duct Nut (1) - Remove [2x]
- Positive Crankcase Ventilation Tube (2) - Disconnect - Plastic Collar Quick Connect Fitting Service
- Air Cleaner Outlet Duct Clamp (3) - Loosen
Disconnect the electrical connector.
- Evaporative Emission Canister Purge Tube (1) - Disconnect - Plastic Collar Quick Connect Fitting Service
- Air Cleaner Outlet Duct Clamp (2) - Loosen
Air Cleaner Outlet Duct (1) - Remove
- CAUTION:
Handle the charge air cooler inlet and outlet air tubes only by the outside surface, making sure to avoid touching the internal seals. Touching the internal seals can dislodge them from their intended location and lead to seal damage and leaks during tube installation.
Release the charge air cooler outlet air hose retainer spring (1).
- Charge Air Cooler Outlet Air Hose (2) - Reposition
Oil Level Indicator (1) - Remove
Oil Level Indicator Tube Bracket Bolt (1) - Remove
Fuel Feed and Evaporative Emission Canister Vent Pipe Clip (1) @ Fuel Feed Front Pipe Bracket (2) - Disengage
- Transmission Vent Hose Clip (3) @ Fuel Feed Front Pipe Bracket (2) - Disengage
Fuel Feed Pipe Bolt (1) - Remove
Evaporative Emission Front Pipe (1) - Disconnect - Plastic Collar Quick Connect Fitting Service
Evaporative Emission Canister Purge Tube (1) - Disconnect - Plastic Collar Quick Connect Fitting Service
Disconnect the electrical connector.
- Evaporative Emission Canister Purge Pump Bolt (1) - Remove [3x]
- Evaporative Emission Canister Purge Pump (2) - Remove
Intake Manifold Cover Bolt (1) - Remove [2x]
- Disconnect the electrical connectors and release the wiring harness retainers as necessary.
- Reposition the engine wiring harness away from the intake manifold.
Intake Manifold Cover (1) - Remove
Intake Manifold Bolt (1) - Remove [6x]
- Intake Manifold (2) - Remove
Intake Manifold Gasket (1) - Remove and DISCARD [4x]
Crankcase Vent Passage Seal (1) - Remove and DISCARD
- Remove underbody panels as necessary. Underbody Panel Component Locator
Radiator Inlet Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Inlet Hose (2) @ Engine Coolant Flow Control Valve - Remove
- NOTE:
Some components not shown for graphic clarity.
Thermostat Bypass Pipe Bolt (1) - Remove
Thermostat Bypass Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Thermostat Bypass Pipe (2) @ Engine Coolant Flow Control Valve - Remove
Engine Oil Cooler Coolant Inlet Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Engine Oil Cooler Coolant Inlet Hose (2) @ Engine Coolant Flow Control Valve - Remove
Exhaust Manifold Outlet Pipe Bolt (2) - Remove
Engine Coolant Thermostat Housing Bracket Bolt (1) - Remove
Thermostat Bypass Hose Clamp (1) @ Exhaust Manifold Outlet Pipe - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Thermostat Bypass Hose (2) @ Exhaust Manifold Outlet Pipe - Remove
Thermostat Bypass Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Engine Coolant Thermostat Housing Inlet Pipe (2) @ Engine Coolant Flow Control Valve - Remove
Electrical Connector (1) @ Engine Coolant Flow Control Valve - Disconnect [3x]
Engine Coolant Flow Control Valve Bolt (1) - Remove [5x]
Engine Coolant Flow Control Valve (1) - Remove
- Engine Coolant Flow Control Valve Seal (2) - 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
Fuel Feed Intermediate Pipe Nut (1) @ Fuel Feed Intermediate Pipe - Loosen [2x]
Fuel Injection Fuel Feed Pipe Bracket Bolt (1) - Remove
- Fuel Feed Intermediate Pipe (2) - Remove and DISCARD
Disconnect the electrical connector. (1)
- Fuel Injection Fuel Rail Bolt (2) - Remove [4x]
Disconnect the electrical connectors. (1)
- Install the EN-49248 Injector Rail Assembly Remover (2).
- Using the EN-49248 Injector Rail Assembly Remover (2), remove the fuel injection fuel rail evenly.
Fuel Injector Retainer (1) - Remove and DISCARD [4x]
- Fuel Injector (2) - Remove [4x]
Fuel Injector Bushing (4) - Remove and DISCARD [4x]
- Fuel Injector Seal (1) - Remove and DISCARD [4x]
- Fuel Injector Seal Spacer (2) - Remove and DISCARD [4x]
- Fuel Injector Nozzle Housing Seal (3) - Remove and DISCARD [8x]
Use care to avoid contact with the fuel rail harness during special tool installation and fuel injection fuel rail removal.