Removal Procedure
- Disconnect the negative battery cable. Battery Negative Cable Disconnection and Connection
- 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 (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)
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.
Radiator Surge Tank Inlet Hose Clamp (1) @ Radiator Surge Tank Inlet Hose - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Surge Tank Inlet Hose Clip (2) @ Engine Control Module Bracket - Remove
- Radiator Surge Tank Inlet Hose Clamp (4) @ Engine Radiator - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Surge Tank Outlet Pipe (3) - Remove
- CAUTION:
Always turn the ignition off when installing or removing the ECM connectors in order to prevent damage to the components.
CAUTION:- Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module in order to prevent internal control module damage.
- Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery.
- In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board.
- Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets, and ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module.
Disconnect the electrical connectors.
- Use a suitable tool to release the locking tabs securing the engine control module to the engine control module bracket.
- Engine Control Module (1) - Remove
Engine Control Module Bracket Bolt (1) - Remove [3x]
Use a suitable tool to release the locking tab and remove the transmission control module (1) by sliding it out from the engine control module bracket (2).
- Engine Control Module Bracket (2) - Remove
Radiator Air Upper Baffle Retainer (1) - Remove [5x]
- Radiator Air Upper Baffle Bolt (2) - Remove [2x]
- Radiator Air Upper Baffle- Upper (3) - Remove
Remove all wiring harness retainers from the front end sheet metal cross braces.
- Front End Sheet Metal Cross Brace Bolt- Left Side and Right Side (1) - Remove [6x]
- Front Suspension Strut Upper Mounting Nut- Left Side and Right Side (2) - Remove [4x]
- Front End Sheet Metal Cross Brace- Left Side and Right Side (3) - Remove [2x]
Air Cleaner Outlet Duct Clamp (1) - Loosen
- Air Cleaner Outlet Duct (2) - Reposition
- Air Cleaner Outlet Duct Clamp (3) - Loosen
- Auxiliary Air Cleaner Outlet Duct (4) - Reposition
Disconnect the 2 mass airflow sensor electrical connectors.
- Remove all retainers from the air cleaner assembly and reposition wiring harnesses as necessary.
- Air Cleaner Bolt (1) - Remove
- Air Cleaner Assembly (2) - Remove
Clamp (1) - Disengage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Charge Air Bypass Valve Vacuum Tank Tube (2) - Disconnect - Plastic Collar Quick Connect Fitting Service
- Charge Air Bypass Valve Vacuum Tank Tube (2) - Remove
Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Turbocharger Wastegate Actuator Vacuum Source Tube (2) - Disconnect - Plastic Collar Quick Connect Fitting Service
- Turbocharger Wastegate Actuator Vacuum Source Tube (2) - Remove
- CAUTION:
The Positive Crankcase Ventilation (PCV) line is tamper resistant and must always be replaced once it is removed. The fittings connected to the PCV line must also be replaced if they are damaged when the PCV line is removed. To reduce the risk of damage to the fittings, use a suitable cutting tool and carefully cut the connections away.
Using a suitable cutting tool, carefully cut the 2 positive crankcase ventilation tube connectors (1).
- Positive Crankcase Ventilation Foul Air Tube (2) - Remove and DISCARD
Charge Air Bypass Valve Hose Clamp (1) - Loosen
- Charge Air Bypass Valve Hose (2) - Reposition
- Retainer Spring (4) - Disengage
Air Cleaner Outlet Duct (1) - Remove
Radiator Outlet Hose Clamp (1) @ Radiator Outlet Pipe - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Outlet Hose (2) @ Radiator Outlet Pipe - Remove
Radiator Outlet Pipe Bolt (1) - Remove
Heater Inlet Hose Retainer (1) - Disengage
- Heater Inlet Hose (2) @ Heater Core - Disconnect and reposition
- Heater Outlet Hose Clamp (3) @ Auxiliary Heater Inlet Hose Tee - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Heater Outlet Hose (4) @ Auxiliary Heater Inlet Hose Tee - Disconnect and reposition
Wiring Harness Retainer (1) - Remove [2x]
Radiator Outlet Pipe Bolt (1) - Remove
- Radiator Outlet Pipe Bolt (2) - Remove
Radiator Outlet Pipe (1) - Remove
- Radiator Outlet Pipe Seal (2) - Remove and DISCARD
Turbocharger Heat Shield Bolt (1) - Remove [3x]
Turbocharger Heat Shield (1) - Remove
Retaining Clip (1) - Remove
Turbocharger Coolant Feed and Return Pipe Bolt (1) - Remove
- Turbocharger Coolant Feed and Return Pipe Gasket (2) - Remove and DISCARD [2x]
- Turbocharger Coolant Return Pipe (3) - Remove
- NOTE:
- Observe the location and routing of the accessory drive primary belt to ensure proper installation.
- Some components not shown for graphic clarity.
Use a suitable tool to rotate the drive belt tensioner (1) counterclockwise to relieve tension from the accessory drive primary belt (2).
- Remove the accessory drive primary belt (2) from the pulleys and tensioner (1).
- Slowly release tension on the drive belt tensioner (1).
- Clean and inspect the drive belt surfaces of all the pulleys.
Charge Air Cooler Coolant Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Charge Air Cooler Coolant Hose (2) @ Auxiliary Water Pump - Remove
Heater Outlet Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Auxiliary Radiator Inlet Pipe (2) @ Auxiliary Water Pump - Remove
Electrical Connector (2) @ Auxiliary Water Pump - Disconnect
- Engine Wiring Harness Retainer (1) @ Charge Air Cooler Coolant Pump Relay Bracket - Remove
- Engine Wiring Harness (3) - Reposition away
Charge Air Cooler Front Bracket Bolt (1) - Remove [2x]
- Auxiliary Water Pump (2) - Remove
Electrical Connector (4) - Disconnect
- Protective Cap (1) - Remove
- Engine Wiring Harness Generator Lead Nut (2) - Remove
- Starter Solenoid Cable (3) - Remove
Generator Bolt (1) - Remove [3X]
- Generator (2) - Remove
Turbocharger Air Inlet Adapter Bolt (1) - Remove [3X]
- Turbocharger Air Inlet Adapter (2) - Remove
- Turbocharger Air Inlet Adapter Seal (3) - Remove and DISCARD
Left side shown, right side similar.