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
Intake Manifold Cover Bolt (1) - Remove
- Oil Filler Cap - 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
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).
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 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).
Disconnect the nitrogen oxides sensor electrical connector.
- 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
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
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
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 Bolt (1) - Remove [5x]
- Charge Air Cooler Bracket (2) - Remove
- Disconnect electrical connectors, reposition 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.
Remove the 2 fuel feed pipe clip bolts (1).
Remove the 2 fuel feed pipe clip bolts (1).
- Unclip the fuel injector fuel return pipe retainer (2).
Fuel Injection Fuel Return Pipe Retainer (1) - Disengage
- Fuel Injection Fuel Return Pipe (2) @ High Pressure Diesel Fuel Injection Rail - Disconnect
Disconnect the 2 high pressure diesel fuel feed to rail pipe fittings (1) from the high pressure diesel fuel injection rail.
- 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.
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.
- NOTE:
Do NOT reuse the high pressure diesel fuel feed pipes.
Remove and DISCARD the 6 high pressure diesel fuel feed to injector pipes (2).
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 the high pressure diesel fuel sensor (1) and fuel pressure regulator (2) electrical connectors.
Disconnect and remove the glow plug wiring harness (1).
Remove the 3 high pressure diesel fuel injection rail nuts (1).
Remove the high pressure diesel fuel injection rail (1).