Removal Procedure
- Turn OFF the engine for 30 seconds before proceeding to purge the fuel pressure from the complete fuel system.
- Drain the cooling system. Cooling System Draining and Filling (Static LM2) , or Cooling System Draining and Filling (GE 47716 LM2)
- Drain the charge air cooling system. Charge Air Cooling System Draining and Filling (GE 47716 LM2) , or Charge Air Cooling System Draining and Filling (Static LM2) , or Charge Air Cooling System Draining and Filling (GE 47716 LM2 with RC1) , or Charge Air Cooling System Draining and Filling (Static LM2 with RC1)
- Plenum Front Panel Outer Reinforcement - Remove - Plenum Front Panel Outer Reinforcement Removal and Installation
Air Cleaner Outlet Front Duct Clamp (1) - Loosen [2x]
- Air Cleaner Outlet Front Duct (2) - Remove
- 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 Duct Clamp (1) - Loosen
- Air Cleaner Outlet Duct (2) - Remove
Engine Wiring Harness Bracket Nut (2) - Remove [3x]
- Disconnect the electrical connectors and detach retainers as needed.
- Engine Wiring Harness (3) - Reposition
Engine Coolant Outlet Pipe Bracket Bolt (1) - Remove
Engine Coolant Air Bleed Hose (2) - Reposition
- 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).
Remove the turbocharger coolant feed and return pipe bolt (3) and position the turbocharger coolant feed pipe (2) out of the way.
Remove the turbocharger coolant return hose clip (1) and position the turbocharger coolant return hose out of the way.
- Remove the exhaust gas recirculation outlet pipe bolt (2).
Remove the 2 exhaust gas recirculation outlet pipe bolts (1).
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) - Disconnect [3x]
- Wiring Harness Retainer (2) @ Charge Air Cooler - Remove [3x]
Wiring Harness Retainer (4) @ Charge Air Cooler - Remove
- Hose Clamp (1) - Disengage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Charge Air Cooler Coolant Pump Hose (2) @ Charge Air Cooler - Disconnect
- Charge Air Cooler Coolant Hose (3) @ Charge Air Cooler - Disconnect
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) - Remove
Upper Intake Manifold Brace Nut (1) - Remove [3x]
- Reposition the upper intake manifold bracket (2) with the nitrogen oxides sensor attached.
Retainer (1) - Unclip
- Remove the exhaust gas recirculation cooler temperature sensor (2) at the compressor air intake turbocharger and position aside.
Turbocharger Heat Shield Bolt (1) - Remove [2x]
- Turbocharger Heat Shield Nut (2) - Remove
Turbocharger Heat Shield (1) - Position aside
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 Bolt (2) - Remove
- 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
Catalytic Converter Clamp (1) - Remove and DISCARD
- Front Wheelhouse Liner-Right Side - Remove - Front Wheelhouse Liner Replacement
{If equipped} Catalytic Converter Brace Bracket Nut (2) - Remove
- {If equipped} Battery Negative Cable Extension Cable Strap (1) @ Catalytic Converter Brace Bracket - Remove
- NOTE:
Quantity of fasteners may vary based on option content.
Catalytic Converter Brace Bracket Nut (1) - Remove [2x]
Catalytic Converter Brace Bracket Nut (1) - Loosen [2x]
Catalytic Converter Brace Bracket Nut (1) - Loosen [2x]
- Reposition the catalytic convertor enough to remove the compressor air intake turbocharger.
Positive Crankcase Ventilation Hose Clamp (1) - Disengage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Positive Crankcase Ventilation Hose (2) - Remove
Exhaust Pressure Differential Sensor Bracket Stud (1) - Remove [2x]
- Exhaust Pressure Differential Sensor Bracket (2) - Reposition
Turbocharger Coolant Feed Hose Clamp (1) @ Water Outlet - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Turbocharger Coolant Feed Hose (2) @ Water Outlet - Disconnect
Detach wiring harness retainers from the heater inlet hose bracket (2) and position the harness aside.
- Remove the exhaust gas recirculation valve bracket nut (1).
- Remove the heater inlet hose bracket (2).
Exhaust Pressure Sensor Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Remove the exhaust pressure differential sensor hose from the exhaust gas recirculation pipe.
Exhaust Gas Recirculation Pipe Nut (1) - Remove
Exhaust Gas Recirculation Pipe Nut (1) - Remove
Exhaust Gas Recirculation Pipe (1) - Reposition
- Exhaust Gas Recirculation Outlet Pipe Gasket (2) - Remove and DISCARD
Disconnect the electrical connector (1).
- Exhaust Gas Recirculation Pipe Bolt (2) - Remove [2x]
Exhaust Gas Recirculation Pipe Bolt (1) - Remove [2x]
Exhaust Gas Recirculation Valve (1) - Remove
- Exhaust Gas Recirculation Valve Cooler Gasket (2) - Remove and DISCARD
Turbocharger Nut (1) - Remove and DISCARD [3x]
Remove the 3 turbocharger studs (3).
- Reposition the turbocharger to allow access to the inboard turbocharger oil feed pipe bolt.
- Cover the exhaust manifold opening to prevent debris from entering the system.
Turbocharger Oil Feed Pipe Bolt (1) - Remove [2x]
- Turbocharger Oil Feed Pipe (2) @ Compressor Air Intake Turbocharger - Disconnect
- Turbocharger Oil Feed Pipe Gasket (3) - Remove and DISCARD
Catalytic Converter Gasket (1) - Remove and DISCARD
Compressor Air Intake Turbocharger (1) - Remove
- Turbocharger Gasket (2) - Remove and DISCARD
- Disconnect electrical connectors, reposition the harness and hoses 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
Fuel Feed Pipe Clip Bolt (1) - Remove
Fuel Pump Fuel Feed Hose (1) - Reposition
Diesel Fuel Separator Bracket Bolt (1) - Remove
Diesel Fuel Separator (1) - Reposition
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
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.
- Remove the high pressure diesel fuel feed to rail pipe (2) from the vehicle 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 injector and the fuel injection rail.
- Remove and DISCARD the 6 high pressure diesel fuel feed to injector pipes (2).
Disconnect the throttle body electrical connector.
- Throttle Body Bolt (1) - Remove [3x]
- Throttle Body (2) - Remove
- Throttle Body Gasket (3) - Remove and DISCARD
Electrical Connector (1, 2) - Disconnect
Disconnect the intake air pressure and temperature sensor electrical connector.
- Intake Air Pressure and Temperature Sensor Bolt (1) - Remove
- Intake Air Pressure and Temperature Sensor (2) - Remove
Disconnect and remove the glow plug wiring harness (1).
Retainer (3) - Remove
- Disengage the 6 fuel injection fuel return pipe locking springs (4).
Fuel Injector Fuel Return Pipe (1) - Reposition
Remove the 3 fuel injection fuel rail nuts (3).
- Remove the high pressure diesel fuel injection rail (2).
- Remove the charge air cooler bracket (1).
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:
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.
Using the EN-52451 Fuel Injector Remover (3) and the EN-51146-1-3 Sliding Hammer (1), remove the 1, 2, 3, 4 high pressure diesel fuel injectors (2).
- Using the EN-52451 Fuel Injector Remover (3) and a suitable tool, rotate the 5, 6 high pressure diesel fuel injectors (2) left and right in its bore until its released from its seats.
Label the 6 fuel injectors (1) to ensure that they are reinstalled in the location from which they were removed.
- Remove the 6 high pressure diesel fuel injectors (1).
- Remove and DISCARD the 6 fuel injector seals (2).
- Remove and DISCARD the 6 fuel injector washers (3).
Engine Coolant Air Bleed Hose Stud (2) - Remove
Oil Filler Tube (3) - Remove
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 Housing (1) - Remove
- Camshaft Housing Gasket (2) - Remove and DISCARD [2x]
Do NOT reuse the high pressure diesel fuel feed pipes.
Do NOT reuse the high pressure diesel fuel feed pipes.
The EN-51146-1-3 Sliding Hammer cannot be used to remove high pressure diesel fuel injectors 5 or 6.