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
- 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
Radiator Surge Tank Inlet Hose Clamp (1) @ Radiator Surge Tank Outlet Pipe (3) - Disengage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Surge Tank Inlet Hose (2) @ Radiator Surge Tank Outlet Pipe (3) - Remove [2x]
Radiator Surge Tank Inlet Hose Clip (1) @ Positive Crankcase Ventilation Hose - Remove
- Radiator Surge Tank Inlet Hose Clip (3) @ Fuel Pump Cover - Remove
- Radiator Surge Tank Inlet Hose Clip (2) @ Engine Wiring Harness - Remove
Radiator Surge Tank Inlet Hose Clip (1) @ Radiator Surge Tank Inlet Pipe Bracket - Remove
- Radiator Surge Tank Inlet Hose Clip (2) @ Radiator Surge Tank Inlet Pipe Bracket - Remove
- Radiator Surge Tank Outlet Pipe (3) - Remove
Retainer (1) @ Intake Manifold (2) - Unclip [7x]
- Wiring Harness (3) - Disconnect and reposition
Radiator Surge Tank Oulet Hose Clip Bracket Nut - Loosen [2x]
- Radiator Surge Tank Inlet Pipe Bracket - Reposition [2x]
Retainer Spring (1) - Release
- Charge Air Cooler Outlet Air Tube (2) @ Throttle Body (3) - Disconnect
Electrical Connector (1) @ Intake Air Pressure and Temperature Sensor - Disconnect
Intake Manifold Bolt (1) - Remove [7x]
- Disconnect throttle body electrical connector (1)
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
Ensure any other retainers are disconnected.