Removal Procedure
- Turn OFF the engine for 30 seconds before proceeding. This will purge the fuel pressure from the complete fuel system.
- Plenum Front Panel Outer Reinforcement - Remove - Plenum Front Panel Outer Reinforcement Removal and Installation
Remove the oil filler cap.
- Intake Manifold Cover Bolt (1) - Remove
- Intake Manifold Cover (2) - Remove
- Install the oil filler cap after removal of the intake manifold cover to prevent debris from falling into the engine.
Air Cleaner Outlet Front Duct Clamp (1) - Loosen [2x]
- Air Cleaner Outlet Front Duct (2) - Remove
Air Cleaner Outlet Duct Clamp (1) - Loosen
- Air Cleaner Outlet Duct (2) - Remove
Remove the 3 engine wiring harness bracket nuts (1).
- Position the rear engine wiring harness channel (2) out of the way.
Engine Coolant Outlet Pipe Bracket Bolt (1) - Remove
- NOTE:
Note: Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.
Remove the 2 exhaust gas recirculation cooler bolts (1).
Turbocharger Coolant Feed and Return Pipe Bolt (3) - Remove
Remove the turbocharger coolant return hose clip (1) and position the turbocharger coolant return hose out of the way.
- Remove the exhaust gas recirculation pipe bolt (2).
Exhaust Gas Recirculation Outlet Pipe Bolt (1) - Remove [2x]
Exhaust Gas Recirculation Pipe (1) - Remove
- Exhaust Gas Recirculation Pipe Seal (2) - Remove and DISCARD
- Exhaust Gas Recirculation Cooler Inlet Pipe Gasket (3) - Remove and DISCARD
Electrical Connector (1) @ Nitrogen Oxides Sensor - Disconnect
- Wiring Harness Retainer (2) @ Charge Air Cooler - Remove [3x]
- Electrical Connector (3) @ Charge Air Cooler - Disconnect [2x]
- Engine Wiring Harness (4) - Position aside
Wiring Harness Retainer (4) @ Charge Air Cooler - Remove
Charge Air Cooler Outlet Air Hose Clamp (1) - Loosen until disengaged [2x]
- Charge Air Cooler Outlet Air Hose (2) - Remove
Charge Air Cooler Inlet Air Hose Clamp (1) - Loosen until disengaged [2x]
- Charge Air Cooler Inlet Air Hose (2) - Remove
Charge Air Cooler Bolt (1) - Remove [4x]
Reposition the charge air cooler (1) with coolant hoses attached.
- NOTE:
The injector fuel label located on the engine charge air cooler will become invalid and MUST be removed and DISCARDED if ANY fuel injector is replaced. The label is only accurate as long as the original fuel injectors are installed.
Remove and DISCARD the injector fuel label (1).
Upper Intake Manifold Brace Nut (1) - Remove [3x]
- Reposition the upper intake manifold bracket (2) with the nitrogen oxides sensor.
Turbocharger Heat Shield Bolt (1) - Remove [2x]
- Turbocharger Heat Shield Nut (2) - Remove
Reposition the turbocharger heat shield (1) with the exhaust gas recirculation temperature sensor attached.
Release the retaining spring (1).
- Intake Manifold Resonator (2) - Remove
Turbocharger Bracket Bolt (1) - Remove
Engine Wiring Harness Bracket Nut (1) - Remove [2x]
- Engine Wiring Harness Bracket (3) - Reposition
Oil Filler Tube Support Stud (1) - Remove
Engine Coolant Air Bleed Hose Clip (1) - Remove
Charge Air Cooler Bolt (1) - Remove [5x]
- Charge Air Cooler Bracket (2) - Remove
Reposition harness, hoses, and connect electrical connectors as needed.
- Exhaust Gas Recirculation Pipe Bracket Bolt (1) - Remove
- Exhaust Gas Recirculation Pipe Bracket (5) - Remove
- 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
Loosen the high pressure diesel fuel feed pipe nuts (1) from the fuel injector and the fuel injection rail, as needed.
Remove and DISCARD the high pressure diesel fuel feed to injector pipe(s), as needed (2).
- NOTE:
Only replace the faulty injector.
Disconnect the high pressure diesel fuel injector electrical connectors (1), as needed.
- Disconnect the fuel injector wiring harness retainers (2), as needed and reposition the fuel injector wiring harness out of the way.
Disengage the fuel return hose connector (4), as needed.
Fuel Injection Fuel Return Pipe (1) - Reposition
Fuel Injector Bolt (1) - Remove
- Multiport Fuel Injector Bracket (2) - Remove
- NOTE:
The EN-52451 Fuel Injector Remover and EN-51146-1-3 Sliding Hammer are only used for high pressure diesel fuel injectors 1, 2, 3, or 4.
Remove the faulty high pressure diesel fuel injector (2) using the EN-52451 Fuel Injector Remover (3) and EN-51146-1-3 Sliding Hammer (1).
- Remove the faulty high pressure diesel fuel injector (2) using the EN-52451 Fuel Injector Remover (3) and a suitable tool, to rotate the high pressure diesel fuel injector left and right in its bore until it is released from its seat.
Remove the faulty high pressure diesel fuel injector (1).
- Using the EN-47909 Injector Bore and Sleeve Cleaning Kit, clean the high pressure diesel fuel injector bores as needed.
The EN-51146-1-3 Sliding Hammer cannot be used to remove high pressure diesel fuel injectors 5 or 6.