Removal Procedure
- Drain the cooling system. Cooling System Draining and Filling (GE-47716) , or Cooling System Draining and Filling (Static)
- Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection (Without KL9) , or Battery Negative Cable Disconnection and Connection (With KL9)
- Drain the engine oil. Engine Oil and Oil Filter Replacement
Air Cleaner Outlet Duct (2) - Remove - Air Cleaner Outlet Duct Replacement
Air Cleaner Assembly (1) - Remove - Air Cleaner Assembly Replacement
Oil Cap (1) - Remove
- Intake Manifold Cover Fastener (2) - Remove
- Intake Manifold Cover (3) - Remove
- Intake Manifold Insulator (4) - Remove
- Charge Air Cooler Outlet Air Tube - Remove - Charge Air Cooler Outlet Air Tube Replacement
Power Brake Booster Vacuum Pipe Fitting (1) @ Vacuum Pump - Disconnect
Engine Coolant Air Bleed Hose (2) @ Turbocharger Coolant Return Pipe - Disconnect - Engine Coolant Air Bleed Hose Replacement (Turbocharger Coolant Return Pipe to Water Outlet, LFV) , or Engine Coolant Air Bleed Hose Replacement (Turbocharger Coolant Return Pipe to Radiator Surge Tank, LFV)
Engine Coolant Air Bleed Hose (2) @ Water Outlet - Disconnect
Engine Wiring Harness Ground Bolt (1) - Remove
- Ground Cable (2) - Reposition away
- Engine Coolant Temperature Sensor Electrical Connector (3) - Disconnect
Clamp (2, 6) - Disengage [4x] - Hose Clamp Replacement Guidelines - Spring Type
- Thermostat Bypass Hose (7) @ Water Outlet (1) - Disconnect
- Radiator Outlet Hose (5) @ Water Outlet (1) - Disconnect
- Heater Inlet Hose (4) @ Water Outlet (1) - Disconnect
- Heater Outlet Hose (3) @ Water Outlet (1) - Disconnect
Thermostat Bypass Pipe Bolt (1) - Remove
Heater Outlet Hose Bracket Bolt (1) - Remove
- Heater Coolant Pump Hose (2) - Reposition away
Water Pump and Air Conditioning Compressor and Generator Belt (2) - Remove - Water Pump, Air Conditioning Compressor, and Generator Belt Replacement
Heated Oxygen Sensor Electrical Connector - Disconnect
Turbocharger Heat Shield Fastener (1) - Remove [6x]
- Turbocharger Heat Shield (2) - Remove
- Front Compartment Splash Shield - Remove - Front Compartment Splash Shield Replacement
Charge Air Cooler Inlet Hose Quick Connector (1) - Disengage
- Charge Air Cooler Inlet Hose (2) @ Charge Air Cooler - Remove
Charge Air Cooler Inlet Hose Quick Connector (1) - Disconnect
- Charge Air Cooler Inlet Hose (2) @ Turbocharger (2) - Remove
Catalytic Converter Brace Bracket Nut (1) - Remove [2x]
Catalytic Converter Clamp Bolt (1) - Loosen
- Exhaust Front Pipe - Remove - Exhaust Front Pipe Replacement (LFV)
Catalytic Converter Brace Bracket Nut (2) - Remove
- Catalytic Converter Brace Bracket (3) - Remove
Catalytic Converter Clamp (2) - Remove
- Warm Up Three-Way Catalytic Converter (3) - Remove
- Catalytic Converter Gasket (1) - Remove and DISCARD
- Catalytic Converter Brace Bracket Nut (4) - Remove [2x]
Turbocharger Oil Return Pipe Bolt (1) - Remove [2x]
- Turbocharger Oil Return Pipe (2) @ Turbocharger - Remove
- Turbocharger Oil Return Pipe Gasket (3) - Remove and DISCARD
Turbocharger Coolant Return Pipe (4) - Remove - Turbocharger Coolant Return Pipe Replacement (LFV)
Turbocharger Coolant Feed Pipe Fastener (1) - Remove.
- Remove and DISCARD the 2 turbocharger coolant feed pipe gaskets (2).
Electrical Connector (1) @ Camshaft Position Actuator Solenoid Valve - Disconnect
- Positive Crankcase Ventilation Tube with Positive Crankcase Ventilation Hose Fitting (2) - Remove
Electrical Connector (2) @ Turbocharger Wastegate Regulator Solenoid Valve - Disconnect
- Disconnect the wiring harness plug (3) from the turbocharger bypass valve solenoid (1).
Turbocharger Nut (2) - Remove and DISCARD [4x]
- Turbocharger (1) - Remove
Remove and DISCARD the turbocharger heat shield with gasket (1).
Ignition Coil Electrical Connector (1) - Disconnect [4x]
Ignition Coil Fastener (1) - Remove [4x]
- Ignition Coil (2) - Remove [4x]
Fuel Feed Front Pipe (1) @ Fuel Pump (2) - Disconnect– Metal Collar Quick Connect Fitting Service
- Use EN-6015 Closure Plugs to cap the open fuel feed connections to prevent contamination.
Engine Wiring Harness Bracket Bolt (1) - Remove [2x]
- Engine Wiring Harness Bracket - (2) 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 Pump Insulator (3) - Remove
- Disconnect the electrical connector. (2)
- NOTE:
Lay a lint-free cloth under the fuel feed intermediate pipe.
Remove the fuel feed intermediate pipe bracket bolt (3).
- Loosen the fuel feed intermediate pipe fittings (2, 5) at the fuel pump (6) and the fuel injection fuel rail (1).
- Remove and DISCARD the fuel feed intermediate pipe (4).
Fuel Injection Fuel Rail Wiring Harness (1) - Disconnect
- Fuel Injection Fuel Rail Assembly - Remove - Fuel Injection Fuel Rail Assembly Replacement
Vacuum Pump Bolt (1) - Remove [3x]
Remove the vacuum pump (1).
- Remove and DISCARD the vacuum pump gasket (2).
- Inspect the vacuum pump seal (3) and replace if necessary. Vacuum Pump Seal Replacement
Retainer (1) - Unclip
- Engine Wiring Harness Bracket Bolt (2) - Remove
- Electrical Connector (8) @ Heated Oxygen Sensor (7) - Disconnect
- Unclip the heated oxygen sensor wiring harness from the engine wiring harness bracket (3).
- Electrical Connector (4) @ Exhaust Camshaft Position Sensor (5) - Disconnect
- Engine Wiring Harness Bracket (3) - Position aside
- Camshaft Cover - Remove - Camshaft Cover Replacement
Evaporative Emission Canister Purge Solenoid Valve Connector (2) - Disconnect
- Evaporative Emission Front Pipe (3) - Disconnect
- Intake Manifold - Remove - Intake Manifold Replacement
Protective Cap (4) - Remove
- Battery Positive Cable Nut (3) - Remove
- Battery Positive Cable (2) - Remove
- Electrical Connector (1) - Disconnect
Generator Bolt (3) - Remove [2X]
- Generator Nut (2) - Remove
- Remove the generator mounting stud, if necessary. (1)
- Remove the generator. (4)
Drive Belt Tensioner Fastener (1) - Remove
- Drive Belt Tensioner (2) - Remove
Upper Oil Pan Bolt (1) - Remove [3x]
Adjust the engine to cylinder 1 top dead center (TDC) of combustion stroke. Set crankshaft in direction of engine rotation until the markings (1, 2) line up. Rotate at the crankshaft balancer bolt (3).
Install the EN-44226-1 remover (2) to the crankshaft balancer (1).
- Loosen the crankshaft balancer bolt (3) by counter holding the crankshaft balancer (1) with the EN-44226-1 remover (3) and a suitable tool.
- Remove the EN-44226-1 remover.
- Crankshaft Balancer Bolt (3) - Remove
Install the EN-44226-5 protector (1) to the crankshaft (2).
Install EN-44226-1 remover (2) and EN-44226-2 remover plate (3) onto the balancer (4).
- Install the EN-44226-3 remover screw (1) through the EN-44226-2 remover plate and against the EN-44226-5 protector.
- Counter hold the EN-44226-2 remover plate and turn the EN-51368 installer screw to remove the balancer.
- Remove the EN-44226 remover.
- Crankshaft Balancer (4) - Remove
- Remove the EN-44226-5 protector.
Install the EN-36857 Engine Lift Bracket with the EN-51768 Engine Support Fixture Adapters as shown.
Install the EN-51007 Global Engine Support Fixture as shown. Engine Support Fixture
- Engine Mount - Remove - Engine Mount Replacement
Engine Mount Brace Bolt (1) - Remove
- Engine Mount Brace Bolt (2) - Remove
- Engine Mount Bracket Reinforcement (3) - Remove
Engine Mount Bracket Bolt (1) - Remove and DISCARD [3x]
- Engine Mount Bracket (2) - Remove
Engine Front Cover Bolt (3, 5) - Remove [11x]
- Engine Front Cover Stud (1) - Remove
- Engine Front Cover Bolt (2) - Remove
- Engine Front Cover Bolt (4) - Remove
Loosen the engine front cover carefully from the engine, use a suitable tool at the location as shown to pry (1, 2, 3).
Engine Front Cover (1) - Remove
- Crankshaft Front Oil Seal (2) - Remove
Install the EN-51367 holder (1).
- Timing Chain Upper Guide Replacement - Remove
The engine has one of the two tensioner designs (1, 2). Each design has a different release mechanism and position.
Fix the timing chain tensioner with design 1 (1) in service position:
Slightly release tension from the piston (2) until bar (1) can be unlocked by rotating the lever (3) in direction of arrow.
Entirely push back the piston (1) until the tensioner lever (2) cannot be locked in this position.
Release tension from the piston (1) until it releases for three ratchets. The three ratchets can be noticed by the click noises.
Apply tension to the piston until the lever (1) is rotated back into the locking position where the bore in the lever aligns with the bore in the tensioner housing.
- Fix the lever in this position with a suitable fixing pin (2).
The style of tensioner design 2 (1) can be released by using a punch and pressing on the release clip (2).
- Secure the timing chain tensioner with suitable sized drill bit (3).
Timing Chain Tensioner Shoe Bolt (1) - Remove
- Timing Chain Tensioner Shoe (2) - Remove
- NOTE:
Both tensioner designs have the same removal procedure.
Ensure the correct fixation of the tool (3).
- Timing Chain Tensioner Bolt (4) - Remove [2x]
- Timing Chain Tensioner (1) - Remove
- Remove and DISCARD the gasket. (2)
Timing Chain (1) - Remove
Timing Chain Guide Bolt (2) - Remove [3x]
- Timing Chain Guide (1) - Remove
Install the EN-36857 Engine Lift Bracket (1) to the engine block, then install the EN-51768 Engine Support Fixture Adapter (2).
- Position the engine support fixture hook (3) to the newly installed EN-36857 Engine Lift Bracket (1).
- Remove the engine support fixture hook from the EN-36857 Engine Lift Bracket mounted to the cylinder head.
EN-51768 Engine Support Fixture Adapter (2) - Remove
- EN-36857 Engine Lift Bracket (1) - Remove
Loosen the 10 cylinder head bolts in sequence as shown.
- CAUTION:
In order to prevent damage to the valves and injectors during cylinder head removal, set the cylinder head on blocks.
Cylinder Head Bolt (2) - Remove and DISCARD [10x]
- Cylinder Head (1) - Remove
- Cylinder Head Gasket (3) - Remove and DISCARD
Remove the oil pan bolts. (2) [12x]
- Loosen the lower oil pan (3) carefully from the upper oil pan, use a suitable tool to pry at the locations (1) as shown.
Remove the oil pan drain plug, if applicable.
- Lower Oil Pan (2) - Remove and DISCARD
Electrical Connector (1) @ Engine Oil Level Indicator Control Module Wiring Harness (2) - Disconnect
Electrical Connector (2) @ Oil Pump Flow Control Solenoid Valve (1) - Disconnect
Transmission Bolt (1) - Remove [2x]
- Transmission Cover (2) Remove
- NOTE:
Take note that there are different bolt lengths.
Oil Pan Bolt (3) -Short - Remove [12x]
- Oil Pan Bolt (2) -Medium - Remove [2x]
- Oil Pan Bolt (1) -Long - Remove [2x]
Loosen the upper oil pan (2) carefully from the engine block, use a suitable tool at the location as shown to pry (1).
- Upper Oil Pan (2) - Remove
- Oil Pump - Remove - Oil Pump Replacement
- Crankshaft Oil Deflector - Remove - Crankshaft Oil Deflector Replacement (With PCV Oil Drain Pipe) , or Crankshaft Oil Deflector Replacement (Without PCV Oil Drain Pipe)
- NOTE:
Many internal engine components will develop specific wear patterns on their friction surfaces.
Components MUST be separated, marked, or organized in a way to ensure installation to their original location and position. Take precautions in order to prevent interchanging of parts.
- Tag or mark each part immediately when removed. Indicate location, direction, or orientation when necessary.
- Before removing the connecting rods, check the connecting rod side clearance using the following procedure:
- Tap the connecting rod to one end of the crankshaft journal with a dead-blow or wooden hammer.
- Using feeler gauges, measure the clearance between the crankshaft counterweight and the connecting rod.
- The connecting rod side clearance should not exceed specifications. Engine Mechanical Specifications
- If the end play exceeds the specified limits, measure the width of the crankpin end of the connecting rod. Piston, Connecting Rod, and Bearing Cleaning and Inspection .
- If the connecting rod width is significantly smaller than specified and severe wear is present on the side of the connecting rod, replace the connecting rod.
- If the connecting rod width is within specification and excessive scoring is present on the crankshaft journals, replace the crankshaft.
- Using a marker, number each piston face. Draw an arrow along the centerline of the piston pointing toward the front of the engine.
- Mark the cylinder number on the connecting rod and the connecting rod cap with a scribe, paint stick or permanent marker.
- Connecting Rod Bolt (3) - Remove and DISCARD [4x]
- Remove the 2 connecting rod bearing caps (2).
- Connecting Rod Bearing (1) - Remove [2x]
- Lower the vehicle.
Push the 2 pistons (1) with the 2 connecting rods (2) out of the cylinder 2 and the cylinder 3 upwards.
- Connecting Rod Bearing (3) - Remove [2x]
- Raise the vehicle.
Crankshaft Pulley Bolt (1) - Install
- Rotate the crankshaft 180 degreesto set the cylinder 2 to TDC
Connecting Rod Bolt (3) - Remove and DISCARD [4x]
- Remove the 2 connecting rod bearing caps (2).
- Connecting Rod Bearing (1) - Remove [2x]
- Lower the vehicle.
Push the 2 pistons (1) with the 2 connecting rods (2) out of the cylinder 1 and the cylinder 4 upwards.
- Connecting Rod Bearing (3) - Remove [2x]
- Piston and Connecting Rod Assembly - Disassemble - Piston and Connecting Rod Disassemble
The PCV hose and fitting assembly connection is permanent. Reinstall these components as an assembly unless new components are being used.
Always replace the used oil pan with a new oil pan. The lower oil pan becomes damaged during removal and oil leaks may occur if it is not replaced with a new oil pan.
An arrow/dot showing proper piston orientation is located on the top of the piston.
Do not use a stamp, punch or any other method that may distort or stress the connecting rod or connecting rod cap. Extensive engine damage may result from a connecting rod that is distorted or stressed.
Powdered metal connecting rods have rod bolts which yield when torqued. If the rod bolts are loosened or removed the rod bolts must be replaced. Rod bolts that are not replaced will not torque to the correct clamp load and can lead to serious engine damage.