Removal Procedure
- Relieve the fuel system pressure. Fuel Pressure Relief
- Drain the charge air cooling system. Cooling System Draining and Filling (LSY GE 47716) , or Cooling System Draining and Filling (LSY Static Fill) , or Cooling System Draining and Filling (LSY with V03 Static Fill) , or Cooling System Draining and Filling (L3B Static Fill) , or Cooling System Draining and Filling (L3B GE 47716) , or Cooling System Draining and Filling (LSY with V03 GE 47716) , or Cooling System Draining and Filling (LF4 Static Fill) , or Cooling System Draining and Filling (LF4 GE 47716)
- Oil Filler Cap - Remove
Intake Manifold Cover Bolt (1) - Remove
- Intake Manifold Cover (2) - Remove
- Install the oil filler cap after removal of the intake manifold cover to prevent debris from falling into the engine.
Evaporative Emission Canister Purge Tube (1) - Disconnect [2x] - Plastic Collar Quick Connect Fitting Service
- Evaporative Emission Canister Purge Tube (1) - Remove
Disconnect the turbocharger wastegate regulator solenoid valve electrical connector.
- Turbocharger Wastegate Actuator Vacuum Tank Bolt (3) - Remove [2x]
Disconnect the turbocharger wastegate regulator solenoid valve electrical connector.
- Turbocharger Wastegate Actuator Vacuum Tank Bolt (3) - Remove [2x]
Turbocharger Wastegate Actuator Vacuum Tank Solenoid Valve Tube (3) @ Auxiliary Air Cleaner Outlet Duct - Disconnect - Plastic Collar Quick Connect Fitting Service
Charge Air Bypass Valve Vacuum Tank Tube (3) - Disconnect - Plastic Collar Quick Connect Fitting Service
Turbocharger Wastegate Actuator Vacuum Source Tube (1) @ Vacuum Pump - Disconnect - Plastic Collar Quick Connect Fitting Service
Charge Air Bypass Valve Tube (1) @ Charge Air Bypass Valve - Disconnect - Plastic Collar Quick Connect Fitting Service
Electrical Connector (1) @ Charge Air Bypass Valve (2) - Disconnect
Charge Air Bypass Valve Tube (1) @ Charge Air Bypass Valve - Disconnect - Plastic Collar Quick Connect Fitting Service
Electrical Connector (1) @ Charge Air Bypass Valve (2) - Disconnect
Turbocharger Wastegate Actuator Vacuum Tank Bolt (1) - Remove [2x]
- Turbocharger Wastegate Actuator Vacuum Tank (2) - Remove
Charge Air Cooler Coolant Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Charge Air Cooler Coolant Hose (2) - Remove
- Charge Air Cooler Coolant Hose Clamp (3) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Charge Air Cooler Coolant Hose (4) - Remove
Charge Air Cooler Coolant Manifold Bolt (1) - Remove [4x]
Supercharger Water Manifold (1) - Remove
- Supercharger Water Manifold Gasket (2) - Remove and DISCARD [2x]
- Charge Air Cooler Coolant Pipe Seal (3) - Remove and DISCARD [4x]
Charge Air Bypass Valve Hose Clamp (1) - Loosen
- Charge Air Bypass Valve Tube Connector Clamp (2) - Loosen
- Charge Air Bypass Valve (3) - Remove
Charge Air Cooler Inlet Air Tube Bolt (1) - Remove [2x]
- Charge Air Bypass Valve Tube Connector Clamp (2) - Loosen
- Charge Air Cooler Inlet Pipe (3) - Remove
- Charge Air Cooler Inlet Air Tube Seal (4) - Remove and DISCARD
Charge Air Bypass Valve Hose Clamp (1) - Loosen
- Charge Air Bypass Valve Tube Connector Clamp (2) - Loosen
- Charge Air Bypass Valve (3) - Remove
Charge Air Cooler Inlet Air Tube Bolt (1) - Remove [2x]
- Charge Air Bypass Valve Tube Connector Clamp (2) - Loosen
- Charge Air Cooler Inlet Pipe (3) - Remove
- Charge Air Cooler Inlet Air Tube Seal (4) - Remove and DISCARD
- NOTE:
Some components not shown for graphic clarity.
Disconnect the electrical connector.
- Charge Air Cooler Bolt (1) - Remove [2x]
- Charge Air Cooler Cover Bolt (2) - Remove [12x]
- NOTE:
Some components not shown for graphic clarity.
Charge Air Cooler Cover (1) - Remove
- Intake Manifold Gasket (2) - Remove and DISCARD
- Charge Air Cooler Cover Seal (3) - Remove and DISCARD [2x]
- NOTE:
Some components not shown for graphic clarity.
Positive Crankcase Ventilation Tube Connector (1) - Disconnect [2x] - Plastic Collar Quick Connect Fitting Service
- Positive Crankcase Ventilation Foul Air Tube (2) - Remove
Engine Rear Noise Shield Bolt (1) - Remove
Windshield Wiper Arm (3) - Remove [2x]
- Using the appropriate trim tool, remove the windshield wiper arm finish cap (1) from the windshield wiper arm (3).
- Windshield Wiper Arm Nut (2) - Remove
- Grasp the outer end of the windshield wiper arm (3) and gently rock the arm back and forth to remove it from the windshield wiper transmission pivot shaft.
Air Inlet Grille Panel Extension (1) - Remove [2x]
- Apply two layers of masking tape around the top edge of the service part to prevent paint damage.
- Using a suitable plastic trim tool, carefully release the air inlet grille panel extension clips.
- Remove the air inlet grille panel extension (1) from the air inlet grille panel and upper front fender.
Front Compartment Side Sight Shield Retainer (1) - Remove [3x]
- Front Compartment Side Sight Shield (2) - Remove
Remove the 2 hood rear outer air inlet seal retainer (1) from the left and right side.
- Remove the hood rear outer air inlet seal (2) from the left and right side.
Air Inlet Grille Panel Retainer (1) - Remove [2x]
- Air Inlet Grille Panel Extension (2) - Remove
Air Inlet Grille Panel Retainer (1) - Remove [6x]
- Air Inlet Grille Panel (2) - Remove
- Disconnect the windshield washer nozzle hose from the windshield washer pump hose.
- Lift the front edge of the air inlet grille panel (2) and slide the panel forward from both hood hinges to remove.
Windshield Wiper System Module Shield (1) - Remove
- Disconnect the battery negative cable. - Battery Negative Cable Disconnection and Connection
Disconnect the windshield wiper motor electrical connector.
- Windshield Wiper System Module Bolt (1) - Remove [2x]
- Slide the windshield wiper system module (2) inboard to release the grommet from the plenum and remove the windshield wiper system module (2) from the vehicle.
Air Inlet Deflector Water Deflector Retainer (1) - Remove [2x]
Air Inlet Deflector Water Deflector (1) - Remove
Plenum Front Panel Nut (1) - Remove [3x]
- Plenum Front Panel Bolt (2) - Remove [3x]
- Disconnect the electrical connector.
- Pull the forward lamp wiring harness (3) out from the plenum front panel.
Plenum Front Panel Bolt (1) - Remove [4x]
- Plenum Front Panel Nut (2) - Remove [3x]
Plenum Front Panel (1) - Remove
- NOTE:
This is a push nut.
Plenum Panel Nut (1) - Remove [9x]
- Dash Panel Outer Upper Insulator (2) - Remove
- Plenum Front Panel (3) - Remove
Engine Rear Noise Shield Bolt (1) - Remove [2x]
- Retainer (2) - Unclip [3x]
- Wiring Harness (3) - Reposition
Fuel Pipe Shield (1) - Remove
Disconnect all electrical connectors.
- Lower Intake Manifold Bolt (1) - Remove [6x]
Intake Manifold (1) - Remove
- Lower Intake Manifold Gasket (2) - Remove and DISCARD [6x]
- WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling 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
- WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling 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.
Engine Rear Noise Shield (1) - Remove
- CAUTION:
Fuel feed intermediate pipes will be delivered with shipping caps that are meant to protect the mating joint threads. Do NOT remove shipping caps until the pipe is to be installed and joints are to be secured. Failure to do so could result in damage to the mating threads.
NOTE:Do NOT reuse the fuel feed intermediate pipe. If the fuel feed intermediate pipe fittings are loosened or the pipes are removed, the pipes MUST be replaced.
Fuel Feed Intermediate Pipe Nut (1) @ Fuel Feed Intermediate Pipe (2) - Loosen until disengaged [3x]
- Fuel Feed Intermediate Pipe (2) - Remove and DISCARD
- NOTE:
The fuel injection fuel rail bolts are retained in the fuel rail by keepers and may be difficult to remove.
Fuel Injection Fuel Rail Bolt (1) - Remove [4x]
- Disconnect the fuel injection fuel rail electrical connectors and remove the 2 retainers from the fuel feed pipe bracket.
- NOTE:
The fuel injection fuel rail bank 1 bolts must be removed for clearance purposes.
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 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 2 sets of the EN-49248 Injector Rail Assembly Remover (1).
- Use the EN-49248 - 4 Hooks (1) to slowly work the fuel injection fuel rail (2) upwards in small, even increments.
- Once the fuel injection fuel rail (2) is free, remove the EN-49248 Injector Rail Assembly Remover components (1).
- 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 fuel injection fuel rail (1) and remove the fuel rail assembly from the cylinder head.
Wiring Harness Retainer (1) - Disengage [2x]
- Disconnect the 3 fuel injection fuel rail electrical connectors (2).
- Fuel Injection Fuel Rail Wiring Harness (3) - Remove
Remove and DISCARD the fuel injector retainer (1) from the fuel injector (2).
- Remove the fuel injector (2) from the fuel rail.
- Fuel Injection Fuel Rail Seal (3) - Remove and DISCARD
Remove and DISCARD the fuel injector nozzle housing seals (1) from the injectors that remain in the fuel rail.
To prevent erroneous DTC's, disconnect the battery negative cable before disconnecting the windshield wiper motor electrical connector.