Removal Procedure
- Drain the 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 (LSY with V03 GE 47716)
- Disconnect the battery. Battery Negative Cable Disconnection and Connection
- Remove the oil fill cap.
Lift up on the front of the intake manifold cover (1).
Intake Manifold Cover (1) @ Upper Intake Manifold Bracket (2) - Remove
Oil Level Indicator (1) - Remove
Disconnect the electrical connector. (1)
- Electrical Connector (1) @ Oil Level Indicator (3) - Unclip
- Oil Level Indicator Tube Bracket Bolt (2) - Remove
Oil Level Indicator Tube (1) - Remove
- Oil Level Indicator Tube Seal (2) - Remove and DISCARD
Electrical Connector (1) - Disconnect [3x]
- Retainer (2) @ Upper Intake Manifold Bracket (3) - Unclip [3x]
- Wiring Harness (4) - Reposition
Upper Intake Manifold Cover Bracket Bolt (1) @ Upper Intake Manifold Bracket (2) - Remove [2x]
Upper Intake Manifold Cover Nut (1) - Remove [2x]
- Upper Intake Manifold Bracket (2) - Remove
Disconnect the evaporative emission canister purge tube quick connects (1). Plastic Collar Quick Connect Fitting Service
- Disconnect the evaporative emission canister purge tube (2) from the retainer (3).
- Evaporative Emission Canister Purge Tube (2) - Remove
Disconnect the quick connect. Plastic Collar Quick Connect Fitting Service
- Evaporative Emission Pipe (1) - Reposition away
Disconnect the electrical connector from the evaporative emission canister purge pump.
- Evaporative Emission Canister Purge Pump Bolt (1) - Remove [3x]
- Evaporative Emission Canister Purge Pump (2) - Remove
Retainer (1) @ Intake Manifold (2) - Unclip [7x]
- Wiring Harness (3) - Disconnect and reposition
Radiator Surge Tank Outlet Hose Clip Bracket Nut (1) - Loosen
- Radiator Surge Tank Inlet Pipe Bracket (2) - Reposition
Retainer Spring (1) @ Throttle Body (3) - Release
- Charge Air Cooler Outlet Air Tube (2) - Disconnect
Charge Air Cooler Outlet Air Tube (2) - Reposition away
- Electrical Connector (1) @ Throttle Body (3) - Disconnect
Intake Manifold Bolt (1) - Remove [7x]
Intake Manifold (1) - Remove
- Intake Manifold Gasket (2) - Remove and DISCARD
Hose Clamp (1) - Disengage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Thermostat Bypass Hose (2) @ Engine Coolant Flow Control Valve - Remove
- Radiator Inlet Hose (3) @ Engine Coolant Flow Control Valve - Remove
Hose Clamp (1) - Disengage [3x] - Hose Clamp Replacement Guidelines - Spring Type
- Engine Coolant Air Bleed Hose (2) @ Engine Coolant Flow Control Valve - Remove
- Engine Coolant Air Bleed Hose (3) @ Engine Coolant Flow Control Valve - Remove
- Engine Oil Cooler Coolant Inlet Hose (4) @ Engine Coolant Flow Control Valve - Remove
Electrical Connector (1) @ Engine Coolant Flow Control Valve - Disconnect [2x]
- Electrical Connector (2) @ Engine Coolant Temperature Sensor - Disconnect
Engine Coolant Flow Control Valve Bolt (1) - Remove [4x]
Engine Coolant Flow Control Valve (1) - Remove
- Water Outlet Seal (2) - Remove and DISCARD
Wiring Harness (2) @ Fuel Injection Fuel Rail Insulator (1) - Position aside
- 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 Insulator (1) - Remove
Electrical Connector @ Fuel Injection Fuel Rail Fuel Pressure Sensor - Disconnect
- Electrical Connector @ Direct Fuel Injector - Disconnect [4x]
- Electrical Connector @ Knock Sensor - Disconnect
- Electrical Connector @ Engine Coolant Temperature Sensor - Disconnect
- Fuel Injector Wiring Harness (1) - Remove