Removal Procedure
- Disconnect the battery. Battery Negative Cable Disconnection and Connection
- Drain the engine oil. Engine Oil and Oil Filter Replacement
- Drain the cooling system. Cooling System Draining and Filling (L3B Static Fill) , or Cooling System Draining and Filling (L3B GE 47716)
- 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
Wiring Harness Retainer (1) @ Air Cleaner Assembly - Remove [4x]
- Positive Crankcase Ventilation Tube (2) - Disconnect - Plastic Collar Quick Connect Fitting Service
- Evaporative Emission Canister Purge Tube (3) - Disconnect - Plastic Collar Quick Connect Fitting Service
- Electrical Connector (4) - Disconnect [2x]
Air Cleaner Bolt (1) - Remove
- Air Cleaner Outlet Duct Clamp (2) - Loosen
Remove the air cleaner (1) and air cleaner outlet duct (2) as an assembly.
Disconnect and reposition the heated oxygen sensor electrical connector as necessary.
- Using the EN-6179 Heated Oxygen Sensor Remover/Installer, remove the heated oxygen sensor (1).
Turbocharger Heat Shield Bolt (1) - Remove [2x]
Turbocharger Heat Shield Bolt (1) - Remove [2x]
Turbocharger Heat Shield (1) - Remove
Retainer Spring (1) - Release
- Charge Air Cooler Inlet Air Tube (2) @ Turbocharger (3) - Remove
Retainer (1) - Unclip
Water Pump Cover Bolt (1) - Remove [3x]
- Water Pump Cover (2) - Remove
- Install the engine support fixture. Engine Support Fixture
Engine Mount Nut (1) - Remove
- Use the EN-51007 Global Engine Support Fixture to raise the engine off the engine mount.
Engine Mount Bracket Bolt (1) - Remove and DISCARD [4x]
Engine Mount Bracket (1) - Remove
- Ensure the phenolic spacer remains in place.
Exhaust Pipe Clamp (1) - Loosen
Compressor Air Intake Turbocharger Wastegate Actuator Link Spring (1) - Remove
- Compressor Air Intake Turbocharger Wastegate Actuator Link Clip (2) - Remove
- Compressor Air Intake Turbocharger Wastegate Actuator Rod (3) @ Turbocharger Wastegate Actuator - Disconnect
Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Turbocharger Coolant Feed and Return Pipe (2) @ Exhaust Manifold Outlet Pipe - Remove
Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Turbocharger Coolant Feed Hose (2) @ Turbocharger Coolant Feed and Return Pipe - Remove
Turbocharger Coolant Feed and Return Pipe Bolt (1) - Remove [2x]
Turbocharger Coolant Feed and Return Pipe (1) - Remove
- Turbocharger Coolant Feed and Return Pipe Gasket (2) - Remove and DISCARD
Retainer (1) - Disconnect [3x]
- Electrical Connector (2) - Disconnect [2x]
- Reposition the front axle vent hose (3), and electrical harness (4).
- 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.
NOTE:Disconnecting the tamper resistant connections will damage the positive crankcase ventilation tube, it must be replaced after removal.
Use a suitable tool to disconnect the 6 locking tabs at each temper resistant connection.
- Positive Crankcase Ventilation Tube (1) - Remove and DISCARD
Turbocharger Brace Nut (1) - Remove
- Turbocharger Bracket Bolt (2) - Remove [2x]
- Turbocharger Brace (3) - Remove
- Turbocharger Oil Feed Pipe Bolt (4) - Remove [4x]
Turbocharger Nut (1) - Remove [2x]
- Turbocharger Bolt (2) - Remove and DISCARD [2x]
Turbocharger Assembly (1) - Remove
- Turbocharger Gasket (2) - Remove and DISCARD
Turbocharger Oil Feed Pipe Bolt (1) @ Compressor Air Intake Turbocharger - Remove [2x]
- Turbocharger Oil Feed Pipe (2) - Remove
- Turbocharger Oil Return Pipe Gasket (3) - Remove and DISCARD
- Turbocharger Oil Return Pipe Gasket (4) - Remove and DISCARD
- Turbocharger Oil Return Pipe Gasket (5) - Remove and DISCARD
Exhaust Pipe Clamp (1) - Remove and DISCARD
In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.
Avoid contact with HOT components. Wear safety glasses and protective gloves to avoid personal injury.
Refer to Heated Oxygen and Oxygen Sensor Caution .
The use of excessive force may damage the threads in the exhaust manifold/pipe.
The heated oxygen sensor MAY be difficult to remove when the engine temperature is less than 48°C (120°F).
The heated oxygen sensor in-line connector and louvered end MUST be kept clear of all grease, dirt, and other contaminants. Do NOT use cleaning solvents of any type. Do NOT drop or roughly handle the sensor.
Phenolic spacer must be present to prevent galvanic/corrosive reaction and/or excessive temperature conduction between engine mount bracket and engine mount. Replace mount if phenolic spacer is missing or damaged. Failure to ensure phenolic spacer is intact and not damaged can lead to premature failure of engine mount and/or engine mount bracket.
When removing, handling or installing this component wear protective gloves. The sharp edges on the component may be very sharp and may cause injury.