Removal Procedure
- Relieve the fuel system pressure. Fuel Pressure Relief
- Drain the cooling system. Cooling System Draining and Filling (L3B Static Fill) , or Cooling System Draining and Filling (L3B GE 47716)
- Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
Oil Level Indicator (1) - Remove
Oil Level Indicator Tube Bracket Bolt (1) - Remove
Oil Level Indicator Tube (1) - Remove
- Inspect the oil level indicator tube seal (2) and replace as necessary.
- Remove the oil fill cap.
Intake Manifold Cover Bolt (1) - Remove [2x]
- Lift up on the front of the intake manifold cover (2).
Intake Manifold Cover (1) @ Upper Intake Manifold Bracket (2) - Remove
Intake Manifold Cover Bolt (1) - Remove
Intake Manifold Cover Insulator (1) - Remove
- WARNING:
Refer to Diesel/Gasoline Vapors Warning .
WARNING:Refer to Safety Glasses Warning .
Fuel Feed Pipe (1) - Disconnect and reposition
- Evaporative Emission Pipe (2) - Disconnect and reposition
Evaporative Emission Canister Purge Tube (1) - Disconnect and reposition
- Retainer (2) - Unclip [3x]
- Radiator Surge Tank Inlet Hose (3) - Reposition
Throttle Body Electrical Connector (1) - Disconnect
Engine Wiring Harness Bolt (1) - Remove
- Electrical Connector (2) - Disconnect [2x]
- Retainer (3) - Unclip [4x]
- Engine Wiring Harness (4) - Reposition
Evaporative Emission Canister Purge Pump Bolt (1) - Remove [3x]
- Evaporative Emission Canister Purge Pump (2) - Remove
Intake Manifold Cover Bolt (1) - Remove [2x]
- Intake Manifold Cover Stud (2) - Remove [3x]
Upper Intake Manifold Cover (1) - Remove
Retainer Spring (1) - Release
- Charge Air Cooler Outlet Air Tube (2) @ Throttle Body (3) - Remove
Retainer (1) - Unclip
Intake Manifold Bolt (1) - Remove [6x]
Intake Manifold (1) - Remove
Crankcase Vent Passage Seal (4) - Remove and DISCARD
- Intake Manifold Gasket (3) - Remove and DISCARD [4x]
Hose Clamp (1) - Disengage [3x] - Hose Clamp Replacement Guidelines - Spring Type
- Thermostat Bypass Pipe (2) @ Engine Coolant Flow Control Valve - Remove
- Radiator Inlet Hose (3) @ Engine Coolant Flow Control Valve - Remove
- Engine Oil Cooler Coolant Inlet Hose (4) @ Engine Coolant Flow Control Valve - Remove
Hose Clamp (1) - Disengage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Exhaust Manifold Outlet Pipe (2) @ Engine Coolant Flow Control Valve - Remove
- Engine Coolant Thermostat Housing Inlet Pipe (3) @ Engine Coolant Flow Control Valve - Remove
Electrical Connector (1) @ Engine Coolant Temperature Sensor - Disconnect
- Electrical Connector (2) @ Engine Coolant Flow Control Valve - Disconnect [2x]
Engine Coolant Flow Control Valve Bolt (1) - Remove [5x]
Engine Coolant Flow Control Valve (1) - Remove
- Engine Coolant Flow Control Valve Seal (2) - Remove and DISCARD
- 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 Noise Shield (1) - Remove
Refer to Diesel/Gasoline Vapors Warning .
Refer to Safety Glasses Warning .