Removal Procedure
- Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
- Drain the cooling system. Refer to Cooling System Draining and Filling (L3B Static Fill) , or Cooling System Draining and Filling (L3B GE 47716)
- Drain the engine oil. Engine Oil and Oil Filter Replacement (RWD)
- Remove the oil fill cap.
Intake Manifold Cover Bolt (1) - Remove [2x]
- Lift up on the front of the intake manifold cover (2).
Intake Manifold Cover (1) @ Upper Intake Manifold Bracket (2) - Remove
Intake Manifold Cover Bolt (1) - Remove
Intake Manifold Cover Insulator (1) - Remove
- WARNING:
Refer to Diesel/Gasoline Vapors Warning .
WARNING:Refer to Safety Glasses Warning .
Fuel Feed Pipe (1) - Disconnect and reposition
- Evaporative Emission Pipe (2) - Disconnect and reposition
Evaporative Emission Canister Purge Tube (1) - Disconnect and reposition
- Retainer (2) - Unclip [3x]
- Radiator Surge Tank Inlet Hose (3) - Reposition
Throttle Body Electrical Connector (1) - Disconnect
Engine Wiring Harness Bolt (1) - Remove
- Electrical Connector (2) - Disconnect [2x]
- Retainer (3) - Unclip [4x]
- Engine Wiring Harness (4) - Reposition
Evaporative Emission Canister Purge Pump Bolt (1) - Remove [3x]
- Evaporative Emission Canister Purge Pump (2) - Remove
Intake Manifold Cover Bolt (1) - Remove [2x]
- Intake Manifold Cover Stud (2) - Remove [3x]
Upper Intake Manifold Cover (1) - Remove
Oil Level Indicator Tube Bracket Bolt (1) - Remove
- Oil Level Indicator Tube (2) - Remove
Retainer Spring (1) - Release
- Charge Air Cooler Outlet Air Tube (2) @ Throttle Body (3) - Remove
Retainer (1) - Unclip
Intake Manifold Bolt (1) - Remove [6x]
Intake Manifold (1) - Remove
Intake Manifold Gasket (3) - Remove and DISCARD [4x]
- Crankcase Vent Passage Seal (4) - Remove and DISCARD
Hose Clamp (1) - Disengage [3x] - Hose Clamp Replacement Guidelines - Spring Type
- Thermostat Bypass Pipe (2) @ Engine Coolant Flow Control Valve - Remove
- Radiator Inlet Hose (3) @ Engine Coolant Flow Control Valve - Remove
- Engine Oil Cooler Coolant Inlet Hose (4) @ Engine Coolant Flow Control Valve - Remove
Hose Clamp (1) - Disengage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Exhaust Manifold Outlet Pipe (2) @ Engine Coolant Flow Control Valve - Remove
- Engine Coolant Thermostat Housing Inlet Pipe (3) @ Engine Coolant Flow Control Valve - Remove
Electrical Connector (1) @ Engine Coolant Temperature Sensor - Disconnect
- Electrical Connector (2) @ Engine Coolant Flow Control Valve - Disconnect [2x]
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
- Raise and support the vehicle. Lifting and Jacking the Vehicle
Auxiliary Generator Battery Jumper Cable Terminal Nut (1) - Remove
- Auxiliary Generator Battery Jumper Cable (2) - Reposition away
- Retainer (3) - Disengage
Starter Stud (1) - Remove
- Starter Bolt (2) - Remove [2x]
- Reposition the starter to gain access to the electrical connections.
Battery Positive Cable Nut (1) @ Starter Solenoid - Remove
- Auxiliary Generator Battery Jumper Cable (2) - Remove
- Electrical Connector (4) - Disconnect
- Starter (3) - Remove
Positive Crankcase Ventilation Baffle Bolt (1) - Remove [12x]
- Positive Crankcase Ventilation Baffle (2) - Remove
Use the pry points indicated by arrows.