Removal Procedure
- Relieve the fuel system pressure. Fuel Pressure Relief
- 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 (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 [2x]
- Radiator Surge Tank Inlet Pipe Bracket (2) - Reposition [2x]
Retainer Spring (1) @ Throttle Body (3) - Release
- Charge Air Cooler Outlet Air Tube (2) - Disconnect
Disconnect and reposition the intake air pressure and temperature sensor electrical connector (1).
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
- Reposition the wiring harness.@ Fuel Pump
Fuel Injection Fuel Feed Pipe Bolt (1) - Remove
- Fuel Feed Intermediate Pipe (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 (2) - Disconnect
- Electrical Connector (3) - Disconnect
- Fuel Injection Fuel Rail Bolt (1) - Remove [4x]
- NOTE:
Use care to avoid contact with the fuel rail harness during special tool installation and fuel rail removal.
Install the two studs (2) from EN-49248 Injector Rail Assembly Remover to the fuel injection fuel rail bolt holes and hand tighten.
- Install the EN-49248 Injector Rail Assembly Remover (4) onto each stud (2) and engage the hooks to the fuel injection fuel rail.
- Install and tighten the two nuts (1, 3).
- NOTE:
- Turn BOTH handles simultaneously, in small, even increments.
- DO NOT twist the fuel injector fuel rail while removing.
Turn both handles (1) on the EN-49248 Injector Rail Assembly Remover to disengage the fuel injection fuel rail (2).
- Remove the EN-49248 Injector Rail Assembly Remover.
- Direct Fuel Injection Fuel Rail (2) - Remove
- Clean all sealing surfaces.
Electrical Connector @ Fuel Injection Fuel Rail Fuel Pressure Sensor - Disconnect
- Electrical Connector @ Direct Fuel Injector - Disconnect [4x]
- Fuel Injector Wiring Harness (1) - Remove
- Mount Direct Fuel Injection Fuel Rail in Vice.
Fuel Injection Fuel Rail Fuel Pressure Sensor - Remove
Fuel Injector Nozzle Housing Seal (1) - Remove and DISCARD [8x]
- Fuel Injector Retainer (2) - Remove and DISCARD [4x]
- Direct Fuel Injector Hold Down Clamp (3) - Remove and DISCARD [4x]
- Direct Fuel Injector (4) - Remove [4x]
Refer to Diesel/Gasoline Vapors Warning .
Refer to Safety Glasses Warning .