Removal Procedure
- Turn OFF the engine for 30 seconds before proceeding. This will purge the fuel pressure from the complete fuel system.
- Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection (9C1, 5W4) , or Battery Negative Cable Disconnection and Connection (KL9)
- Plenum Front Panel Outer Reinforcement - Remove - Plenum Front Panel Outer Reinforcement Removal and Installation
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 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
Engine Coolant Air Bleed Hose (2) - Reposition away
- 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 outlet pipe 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 outlet pipe bolt (2).
Remove the 2 exhaust gas recirculation 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) @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 charge air cooler (1) with coolant hoses attached.
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 Bracket Bolt (1) - Remove [5x]
- Charge Air Cooler Bracket (2) - Remove
Reposition harness and hoses, then 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
Electrical Connector (1) - Disconnect [7x]
- Retainer (2) - Disengage [9x]
- Fuel Injector Wiring Harness (3) - Remove