Removal Procedure
- Turn OFF the engine for 30 seconds before proceeding. This will purge the fuel pressure from the complete fuel system.
Oil Filler Cap - Remove
- 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 Duct Clamp (1) - Loosen [2x]
- Air Cleaner Outlet Front Duct (2) - Remove
- Plenum Front Panel Outer Reinforcement - Remove - Plenum Front Panel Outer Reinforcement Removal and Installation
Air Cleaner Outlet Duct Clamp (1) - Loosen
- Air Cleaner Outlet Duct (2) - Remove
Remove the 3 rear engine wiring harness channel nuts (1).
- Position the rear engine wiring harness channel (2) out of the way.
Engine Coolant Outlet Pipe Bracket Bolt (1) - Remove
Engine Coolant Air Bleed Hose (2) - Reposition
- 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).
Remove the 2 exhaust gas recirculation pipe bolts (1).
Remove the exhaust gas recirculation pipe (1).
- Remove and DISCARD the exhaust gas recirculation pipe seal (2).
- Remove and DISCARD the exhaust gas recirculation cooler inlet pipe gasket (3).
Electrical Connector (1) @ Charge Air Cooler - Disconnect [2x]
- Wiring Harness Retainer (2) @ Charge Air Cooler - Remove [3x]
Wiring Harness Retainer (4) @ Charge Air Cooler - Remove
- Disconnect the nitrogen oxides sensor electrical connector.
Upper Intake Manifold Brace Nut (1) - Remove [3x]
- Reposition the upper intake manifold bracket (2) with the NOX sensor attached.
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]
Charge Air Cooler - (1) Reposition
Turbocharger Heat Shield Bolt (1) - Remove [2x]
- Turbocharger Heat Shield Nut (2) - Remove
Turbocharger Heat Shield (1) - Reposition
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 Bracket Bolt (1) - Remove [5x]
- Charge Air Cooler Bracket (2) - Remove
Reposition harness, hoses and 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
- Front Wheelhouse Liner-Left Side - Remove - Front Wheelhouse Liner Replacement
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.
Fuel Feed Pipe Clip Bolt (1) - Remove
Fuel Pump Fuel Feed Hose (1) - Disconnect [2x] - Metal Collar Quick Connect Fitting Service
- Fuel Pump Fuel Feed Hose (1) - Remove
Fuel Return Pipe (1) @ Diesel Fuel Separator - Disconnect - Metal Collar Quick Connect Fitting Service
- NOTE:
Disconnect the fuel injector fuel return pipe at the diesel fuel separator only.
Fuel Injector Fuel Return Pipe Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Fuel Injection Fuel Return Pipe (2) - Reposition
Disconnect the 2 high pressure diesel fuel feed to rail pipe fittings (1) from the high pressure diesel fuel pump.
Remove the 2 high pressure diesel fuel feed to rail pipe bracket bolts (1).
Diesel Fuel Separator Bracket Bolt (1) - Remove
Diesel Fuel Separator (1) - Disconnect - Metal Collar Quick Connect Fitting Service
- Diesel Fuel Separator (1) - Remove
- NOTE:
Do NOT reuse the high pressure diesel fuel feed pipes.
Remove the high pressure diesel fuel feed to rail pipe (2) from the vehicle and DISCARD.
- Transmission - Remove - Automatic Transmission Removal and Installation (LM2, 4WD and NP0 without F47) , or Automatic Transmission Removal and Installation (LM2, 4WD and NQH without F47) , or Automatic Transmission Removal and Installation (LM2, 4WD and NP0 with F47) , or Automatic Transmission Removal and Installation (LM2, 4WD and NQH with F47)
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.
- Tighten the EN-52448-1 High Pressure Fuel Pump Tool (1) to the fuel pump access bolt holes using the previously removed 2 timing chain cover bolts (2). Fastener Specifications
Remove and DISCARD the fuel injection pump bolt (1).
Mark the high pressure diesel fuel pump shaft and the fuel injection pump driven sprocket at the slot in the shaft (1). This will help with the alignment of the high pressure diesel fuel pump and the fuel injection pump driven sprocket to keep the pump timed with the engine.
Disconnect the 2 high pressure diesel fuel pump electrical connectors (1).
Reposition hoses and harness, as needed.
- Disconnect the electrical connectors from the engine coolant temperature sensor and the block heater.
- Remove the 3 fuel injection pump bolts (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 high pressure diesel fuel pump (1).
- Remove and DISCARD the fuel injection pump seal (2).
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 .