Removal Procedure
- Engine - Remove - Engine Removal and Installation (4WD, with RC1, without F47) , or Engine Removal and Installation (2WD, with RC1, without F47) , or Engine Removal and Installation (4WD, with RC1, with F47) , or Engine Removal and Installation (2WD, with RC1, with F47) , or Engine Removal and Installation (4WD, with WTX, with F47) , or Engine Removal and Installation (2WD, with WTX, with F47) , or Engine Removal and Installation (4WD, with WTX, without F47) , or Engine Removal and Installation (2WD, with WTX, without F47)
Install the EN-52449 Engine Stand Adapter (2) to the engine block.
- Using the EN-52449 Adapter (2) at the engine, install the engine to a suitable engine stand.
- Remove the EN-52474 Engine Lift Bracket Set.
Install the EN-49979 Crankshaft Holder (1) with EN-956-1 Extension (3)
- Crankshaft Pulley Bolt (2) - Loosen [4x]
Automatic Transmission Flex Plate Bolt (2) - Remove and DISCARD [8x]
- Automatic Transmission Flex Plate (1) - Remove
Remove the EN-49979 Crankshaft Holder (1) with EN-956-1 Extension (3).
Crankshaft Pulley Bolt (2) - Remove [4x]
- Crankshaft Pulley (1) - Remove
Engine Front Cover Bolt (1) - Remove [8x]
- Crankshaft Front Oil Seal (2) - Remove and DISCARD
Crankshaft Pulley Bolt (1) - Install and hand tighten [4x]
- Rotate the crankshaft with a suitable tool in the direction of the arrow at the crankshaft pulley bolts (1), until the following alignment is achieved:
- The crankshaft locking divot (2) aligns with the engine block (3)
- The crankshaft timing mark, dimension a, is at 40 degrees TDC
- Install the EN-52586 Crankshaft Fixing Pin (4).
Timing Chain Cover Bolt (1) - Remove [2x]
- Fuel Pump Access Hole Cover (2) - Remove
- Fuel Pump Access Hole Cover Seal (3) - Remove and DISCARD
Install the EN-52448-1 High Pressure Fuel Pump Tool (1) to the fuel injection pump driven sprocket by inserting the 3 dowels into the sprocket holes.
- Install and tighten the previously removed 2 timing chain cover bolts (2) to secure the EN-52448-1 High Pressure Fuel Pump Tool (1) to the fuel pump access bolt hole. Fastener Specifications
Remove and DISCARD the fuel injection pump bolt (1).
Remove the 2 timing chain cover bolts (2)
- Remove the EN-52448-1 High Pressure Fuel Pump Tool (1).
Remove the 16 timing chain cover bolts (1, 2).
- NOTE:
Avoid prying close to the transmission pins.
Using a suitable tool at the locations indicated by the arrows to pry, loosen the timing chain lower cover carefully from the engine block.
Timing Chain Lower Cover (1) - Remove
Crankshaft Rear Oil Seal (1) - 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.
Camshaft Housing Cover Insulator (1) - Remove
Remove the 2 high pressure diesel fuel feed to rail pipe bracket bolts (1).
- Unclip the fuel injector fuel return pipe retainer (2).
Disconnect the 2 high pressure diesel fuel feed to rail pipe fittings (1) from the high pressure diesel fuel injection rail.
Disconnect the 2 high pressure diesel fuel feed to rail pipe fittings (1) from the high pressure diesel fuel pump.
Fuel Feed Pipe Clip Bolt (1) - Remove
- Fuel Return Pipe Clip Bolt (2) - Remove
Diesel Fuel Separator Bracket Bolt (1) - Remove
- NOTE:
Do NOT reuse the high pressure diesel fuel feed pipes.
Remove the high pressure diesel fuel feed to rail pipe (2) and DISCARD.
Remove the fuel injection fuel feed pipe bracket bolt (1).
- Remove the fuel injection fuel feed pipe bracket (2).
Loosen the 12 high pressure diesel fuel feed pipe nuts (1) from the fuel injectors and the fuel injection rail.
- Remove and DISCARD the 6 high pressure diesel fuel feed to injector pipes (2).
Disconnect and reposition the fuel injector wiring harness, as needed.
- Retainer (3) - Disengage
- Fuel Injection Fuel Return Pipe Locking Spring (4) - Disengage [6x]
Fuel Injection Fuel Return Pipe (1) - Reposition
Disconnect the 6 high pressure diesel fuel injector electrical connectors (1).
- Disconnect the 8 fuel injector wiring harness retainers (2) and reposition the fuel injector wiring harness out of the way.
Fuel Injector Bolt (1) - Remove [6x]
- Multiport Fuel Injector Bracket (2) - Remove [6x]
- NOTE:
Mark the location of the high pressure diesel fuel injectors.
Using the EN-52451 Fuel Injector Remover (3) and EN-51146-1-3 Sliding Hammer (1), remove the 6 high pressure diesel fuel injectors (2).
Remove and DISCARD the 6 fuel injector seals (2) and 6 fuel injector washers (3).
Engine Coolant Air Bleed Hose Stud (2) - Remove
Positive Crankcase Ventilation Hose Clamp (1) - Release [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Positive Crankcase Ventilation Hose (2) - Remove
-
Courtesy of GENERAL MOTORS COMPANY
Turbocharger Oil Return Pipe Bolt (7) - Remove [2x]
- Lower Crankcase Extension Bolt (9) Remove
- Turbocharger Oil Return Pipe Bolt (8) - Remove [2x]
- Turbocharger Nut (2, 4) - Remove and DISCARD [3x]
- Turbocharger Assembly (1) - Remove
- Turbocharger Gasket (3) - Remove and DISCARD
- Turbocharger Oil Return Pipe Gasket (6) - Remove and DISCARD
- Turbocharger Oil Return Pipe Gasket (5) - Remove and DISCARD
Camshaft Housing Cover Bolt (1) - Loosen [7x]
- Camshaft Housing Cover Bolt (2) - Loosen [3x]
- Camshaft Housing Cover Bolt (3) - Loosen [9x]
- Camshaft Housing Cover Bolt (4) - Loosen [7x]
Camshaft Cover (1) - Remove
- Camshaft Housing Gasket (2) - Remove and DISCARD [2x]
- Camshaft Housing Cover Insulator (3) - Remove and DISCARD [26x]
Timing Chain Cover Bolt (3) - Remove [4x]
- Timing Chain Cover Bolt (4) - Remove [2x]
- Timing Chain Upper Cover (1) @ Cylinder Head - Remove
Ensure that the camshaft notches (1) are in the 12 o'clock position.
If the camshaft notches are not in the 12 o'clock position, remove the EN-52586 Crankshaft Fixing Pin and rotate the crankshaft until the camshaft notch is in the 12 o'clock position, and the crankshaft aligns with the EN-52586 Crankshaft Fixing Pin locking location.
- Install the EN-52586 Crankshaft Fixing Pin (4).
-
Courtesy of GENERAL MOTORS COMPANY
Install the EN-52445-1 Camshaft Tool (3) to the camshaft housing.
- Check that the tab (1) of the EN-52445-1 Camshaft Tool (3) sits correctly under the camshaft bearing rear cap (2).
- Check that the pins (6) of the EN-52445-1 Camshaft Tool (3) sit correctly in the camshafts (5).
Install the EN-52445-2 Camshaft Tool (1) on the camshafts.
Crankshaft Position Sensor Bolt (3) - Remove
- Crankshaft Position Sensor (2) - Remove
- Crankshaft Position Sensor Seal (1) - Remove and DISCARD
Install the EN-47634 Holder (1) to the oil pump sprocket (2).
- Hold the EN-956 Extension (4) and loosen the oil pump sprocket bolt (3).
- Remove the EN-47634 Holder (1) and the EN-956 Extension (4).
Oil Pump Sprocket Bolt (1) - Remove
- Oil Pump Sprocket (2) - Remove
- Timing Belt (3) - Remove
Timing Chain Tensioner (2) - Remove
- Timing Chain Tensioner Gasket (1) - Remove and DISCARD
Push the timing chain guide (1) in direction of the arrow to compress the tensioner piston.
- Install one EN-52234 Timing Chain Tensioner Retaining Pin (2) to lock the timing chain tensioner in position.
- Timing Chain Tensioner Bolt (3) - Remove [2x]
- Timing Chain Tensioner (4) - Remove
Timing Chain Guide Bolt (2) - Remove [2x]
- Timing Chain Guide (1) - Remove
Camshaft Sprocket Bolt (3) - Remove and DISCARD
- Camshaft Position Sensor Exciter Wheel (1) - Remove
- Camshaft Sprocket (2) - Remove
Secondary Timing Chain (1) - Remove
Timing Chain Guide Bolt (2) - Remove
- Timing Chain Guide (1) - Remove
Timing Chain Guide Bolt (2) - Remove [2x]
- Remove the timing chain guide (1).
Install the EN-52448-3 Nut (2) to the fuel injection pump driven sprocket (3).
- Install the EN-52448-2 Screw (1) to the EN-52448-3 Nut.
- Press out the fuel injection pump from the fuel injection pump sprocket (3), by screwing in the EN-52448-2 screw (1) into the EN-52448-3 Nut (2).
- Remove the EN-52448-2 Screw (1).
- Remove the EN-52448-3 Nut (2) from the fuel injection pump driven sprocket (3).
Remove the timing chain (1) and the fuel injection pump driven sprocket (2) as an assembly.
Timing Chain Guide (1) - Remove
Remove the timing chain (1) from the fuel injection pump driven sprocket (2).
- Lay the camshaft position sensor exciter wheel facedown on a flat surface to check for straightness and wear.
It is likely you will bend the crankshaft front oil seal during the removal. Use care to not damage the engine block.
Once the EN-52586 Crankshaft Fixing Pin (4) is installed, do not remove until all timing components have been installed.
Engine may have to be rotated slightly to align the EN-52448-1 High Pressure Fuel Pump Tool (1). Rotate the engine using the crankshaft balancer until the mounting holes align.
Refer to Fastener Caution .
Do NOT reuse the high pressure diesel fuel feed pipes.