Removal Procedure
- Remove the oil fill cap.
- Drain the engine oil. Engine Oil and Oil Filter Replacement (RWD) , or Engine Oil and Oil Filter Replacement (AWD)
- 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
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
Electrical Connector (1) @ Oil Level Indicator Tube (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
- Wiring Harness (4) - Reposition
Upper Intake Manifold Cover 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 disconnects (1). Plastic Collar Quick Connect Fitting Service
- Disconnect the evaporative emission canister purge tube (2) from the retainer (3).
Disconnect the electrical connector at the evaporative emission canister purge pump (2).
- Evaporative Emission Pipe (1) @ Evaporative Emission Canister Purge Pump (2) - Disconnect - Plastic Collar Quick Connect Fitting Service
- Evaporative Emission Front Pipe (1) - Reposition away
Evaporative Emission Canister Purge Pump Bolt (1) - Remove [3x]
- Evaporative Emission Canister Purge Pump (2) - Remove
Retainer Spring (1) - Release
- Charge Air Cooler Outlet Air Tube (2) @ Throttle Body (3) - Disconnect and reposition
Electrical Connector (1) @ Intake Air Pressure and Temperature Sensor - Disconnect
Retainer (1) @ Intake Manifold (2) - Unclip [7x]
- Wiring Harness (3) - Disconnect and reposition
Radiator Surge Tank Outlet Hose Clip Bracket Nut (1) - Remove [2x]
- Radiator Surge Tank Inlet Pipe Bracket (2) - Reposition [2x]
Disconnect throttle body electrical connector.
- Intake Manifold Bolt (1) - Remove [7x]
Intake Manifold (1) - Remove
- Intake Manifold Gasket (2) - Remove and DISCARD
Use a suitable tool to rotate the drive belt tensioner (1) counterclockwise and hold.
Accessory Drive Primary Belt (1) - Remove
- Slowly release tension on the drive belt tensioner.
Drive Belt Tensioner Bolt (1) - Loosen
- Drive Belt Tensioner (2) - Reposition
Electrical Connector (1) - Disconnect
- NOTE:
Intake manifold is shown transparent.
Battery Positive Cable Nut (1) @ Generator - Remove
- Auxiliary Generator Battery Jumper Cable (2) - Remove
Remove the upper generator bolt (1).
- Loosen the lower generator bolt (2) until it is disengaged from the generator bracket.
Radiator Inlet Hose Bracket Bolt (1) - Remove
- Radiator Inlet Hose Bracket (2) - Reposition away
Remove the generator (1) and the generator lower mounting bolt (2).
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
- Raise and support the vehicle. Lifting and Jacking the Vehicle
Battery Negative Cable Nut (1) @ Starter Stud - Remove
- Engine Wiring Harness Retainer (2) - Disengage [2x]
- Auxiliary Generator Battery Jumper Cable (3) - Remove
Electrical Connector (1) - Disconnect
Battery Positive Cable Nut (1) @ Starter Solenoid - Remove
- Auxiliary Generator Battery Jumper Cable (2) - Remove
Starter Stud (1) - Remove
- Starter Bolt (2) - Remove [2x]
- Starter (3) - Remove
- Lower the vehicle.
Reposition the wiring harness.
- Positive Crankcase Ventilation Oil Separator Cover Bolt (1) - Remove [11x]
Positive Crankcase Ventilation Oil Separator Cover (1) - Remove
Leave the oil filter in place, or oil will continue to drip.
Ensure any other retainers are disconnected.