Removal Procedure
- Relieve the fuel system pressure. Fuel Pressure Relief
Plenum Front Panel Outer Reinforcement (1) - Remove - Plenum Front Panel Outer Reinforcement Removal and Installation
- Drain the cooling system. Cooling System Draining and Filling (GE 47716 L84, L87) , or Cooling System Draining and Filling (Static L84, L87)
- Engine Oil and Oil Filter - Remove and DISCARD - Engine Oil and Oil Filter Replacement
- Front Wheelhouse Liner - Left Side - Remove - Front Wheelhouse Liner Replacement
- NOTE:
- Some components not shown for graphic clarity.
- Pull only on the spark plug wire boot to remove the wire.
Twist the 4 spark plug wire boots a 1/2 turn and remove the 4 spark plug wires (1) from the 4 gas engine ignition spark plugs (2).
Exhaust Manifold Heat Shield Bolt - Right Side (1) - Remove [3x]
Remove the right exhaust manifold heat shield (1) through the wheel opening.
Exhaust Heat Shield Bolt - Right Side (1) - Remove
- Exhaust Front Pipe Heat Shield - Right Side (2) - Remove
Retainer Clip (1) @ Cylinder Head - Right Side (2) - Remove
Disconnect the heated oxygen sensor electrical connector.
- 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.
- The heated oxygen sensor MAY be difficult to remove when the engine temperature is less than 48°C (120°F).
- Using a suitable tool, remove the heated oxygen sensor (1).
Exhaust Front Pipe Nut - Right Side (1) - Remove [3x]
Exhaust Manifold Bolt - Right Side (1) - Remove and DISCARD [5x]
Exhaust Manifold - Right Side (1) - Remove
- Exhaust Manifold Gasket - Right Side (2) - Remove and DISCARD
Exhaust System Seal - Right Side (1) - Remove and DISCARD
- Lower the vehicle.
Positive Crankcase Ventilation Tube Connector (2) @ Air Cleaner Outlet Duct - Disconnect - Plastic Collar Quick Connect Fitting Service
- Positive Crankcase Ventilation Tube Connector (3) @ Positive Crankcase Ventilation Fitting - Disconnect - Plastic Collar Quick Connect Fitting Service
- Positive Crankcase Ventilation Fresh Air Tube (1) - Remove
Air Cleaner Outlet Duct Bracket Bolt (1) - Remove
- Disconnect the electrical connector and retainers as needed.
Air Cleaner Outlet Duct Clamp (2) - Loosen [2x]
- Air Cleaner Outlet Duct (3) - Remove
Oil Level Indicator Tube Bolt (1) @ Cylinder Head - Right Side - Remove
Evaporative Emission Canister Purge Tube Connector (1) @ Evaporative Emission Canister Purge Solenoid Valve - Disengage - Plastic Collar Quick Connect Fitting Service
- Evaporative Emission Canister Purge Tube (2) @ Evaporative Emission Canister Purge Solenoid Valve - Remove and position aside
Engine Wiring Harness Connector (1) @ Throttle Body - Disconnect
- Engine Wiring Harness Retainer (2) @ Intake Manifold Cover - Remove [2x]
- Engine Wiring Harness Connector (3) @ Manifold Absolute Pressure Sensor - Disconnect
- Engine Wiring Harness Connector (4) @ Evaporative Emission Canister Purge Solenoid Valve - Disconnect
Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) - Remove [4x]
Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) - Remove [3x]
Positive Crankcase Ventilation Tube Connector (1) @ Intake Manifold - Disconnect and reposition - Plastic Collar Quick Connect Fitting Service
- NOTE:
Some components not shown for graphic clarity.
Loosen the 10 intake manifold bolts (1) until the bolts are no longer threaded into the cylinder heads.
- Move the intake manifold and intake manifold cover (2) forward enough to gain access to the rear engine wiring harness retainers.
Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) - Remove [4x]
- NOTE:
The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness.
Remove the intake manifold and intake manifold cover (1) as an assembly.
- Cover the cylinder head passages in order to prevent dirt or debris from entering the passages.
Intake Manifold Gasket (1) - Remove and DISCARD [8x]
- 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 (1) - Remove
- CAUTION:
Fuel feed intermediate pipes will be delivered with shipping caps that are meant to protect the mating joint threads. Do NOT remove shipping caps until the pipe is to be installed and joints are to be secured. Failure to do so could result in damage to the mating threads.
NOTE:Do NOT reuse the fuel feed intermediate pipe (2). If the 2 fuel feed intermediate pipe nuts (1) are loosened or the fuel feed intermediate pipes are removed, the fuel feed intermediate pipes MUST be replaced.
Fuel Feed Intermediate Pipe Nut (1) @ Fuel Feed Intermediate Pipe (2) - Loosen until disengaged [2x]
- Fuel Feed Intermediate Pipe (2) - Remove and DISCARD
- Disconnect the electrical wiring harness connectors from the fuel rails as needed.
- NOTE:
Do NOT reuse the fuel feed intermediate pipe (3). If the 2 fuel feed intermediate pipe nuts (1) are loosened or the fuel feed intermediate pipes are removed, the fuel feed intermediate pipes MUST be replaced.
Fuel Feed Intermediate Pipe Nut (1) - Loosen until disengaged [2x]
- Fuel Feed Pipe Bolt (2) - Remove
- Fuel Feed Intermediate Pipe (3) - Remove and DISCARD
Grasp the valve rocker arm cover insulator (3) and lift up disengaging the 3 upper intake manifold sight shield grommets (1) from the 3 valve rocker arm cover insulator retainers (2).
- Valve Rocker Arm Cover Insulator (3) - Remove
- Inspect the 3 upper intake manifold sight shield grommets (1) on the valve rocker arm cover insulator (3) and replace as necessary.
Heater Hose Clip Bracket Bolt (1) - Remove
- Heater Inlet and Outlet Hose Bracket (2) - Reposition
- Engine Wiring Harness Connector @ Ignition Coil - Disconnect [4x]
Valve Rocker Arm Cover Bolt (1) - Loosen until disengaged [10x]
- Valve Rocker Arm Cover - Right Side (2) - Remove
Valve Rocker Arm Cover Gasket (2) @ Valve Rocker Arm Cover (1) - Remove and DISCARD
- NOTE:
- Only replace the valve rocker arms and valve push rods as required.
- The rocker arm pivot support bolts are not serviced separately.
- Place the valve rocker arms and valve push rods in a rack so they can be installed in the same location from which they were removed.
Valve Rocker Arm Pivot Support Bolt (1) - Loosen until disengaged [8x]
- Valve Rocker Arm (2) - Remove [8x]
Valve Push Rod (1) - Remove [8x]
- NOTE:
Some components not shown for graphic clarity.
Engine Wiring Harness Ground Bolt (1) - Remove
- Engine Wiring Harness (2) @ Cylinder Head - Disconnect
Generator Bolt (1) - Loosen until disengaged
- CAUTION:
This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.
Cylinder Head Bolt (1) - Remove and DISCARD [10x]
- CAUTION:
After removal, place the cylinder head on 2 wood blocks in order to prevent damage to the sealing surfaces.
Cylinder Head (1) - Remove
- Cylinder Head Gasket (2) - Remove and DISCARD
- NOTE:
- Organize and mark the valve lifters (1), valve lifter guides (2), and valve lifter guide bolts (3) so they can be installed to their original location.
- The valve lifter guide bolt must match the valve lifter guide it came with. If the valve lifter guide bolt requires replacement, replace the valve lifter guide as well.
- Only replace the valve lifters (1), valve lifter guides (2), and valve lifter guide bolts (3) as required.
Valve Lifter Guide Bolt (3) - Loosen until disengaged
- Remove the valve lifter guide (2) and the valve lifters (1) as an assembly.
Valve Lifter (1) @ Valve Lifter Guide (2) - Remove
- Using the appropriate tool, clean and prepare the applicable sealing surface.
Refer to Heated Oxygen and Oxygen Sensor Caution .
Note the installed position of the valve lifter guides (2). The notched area of the valve lifter guides (2) align with the locating tab on the engine block.