Removal Procedure
- Recover the refrigerant. Refrigerant Recovery and Recharging
Plenum Front Panel Outer Reinforcement (1) - 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.
Battery Hold Down Strap Bolt (1) - Remove [2x]
- Battery Hold Down Strap (2) - Reposition
Retaining Tab (1) - Disengage [2x]
- Front Compartment Fuse Block Cover (2) - Remove
Battery Positive Post Clamp Nut (1) - Loosen
Electrical Connector (1) - Disconnect
Retaining Tab (1) - Disengage [3x]
- Battery Distribution Engine Compartment Fuse Block (2) - Reposition
Battery Hold Down Retainer Bolt (1) - Remove
- Battery Hold Down Retainer (2) - Remove
Battery (1) - Remove
Retaining Tab (1) - Disengage [2x]
- Engine Wiring Harness Junction Block Cover (2) - Remove
- Battery Positive Cable Nut (3) - Remove
- Starter Solenoid Cable (4) - Remove
Engine Wiring Harness Junction Block Bolt (2) - Loosen [4x]
- Retaining Tab (1) - Disengage [4x]
- Engine Wiring Harness Junction Block (3) - Remove
Electrical Connector (1) - Remove [4x]
Engine Wiring Harness Fuse Block Bracket Bolt (2) - Remove [2x]
- Retaining Tab (1) - Disengage
- Engine Wiring Harness Fuse Block Bracket (3) - Remove
Air Conditioning Compressor and Condenser Hose Nut (2) @Air Conditioning Refrigerant Heat Exchanger - Remove
- Air Conditioning Compressor and Condenser Hose (3) @Air Conditioning Refrigerant Heat Exchanger - Remove
- Air Conditioning Compressor and Condenser Hose Seal (4) - Remove and DISCARD
- Air Conditioning Condenser and Evaporator Hose Clip (6) - Remove
- Air Conditioning Condenser and Evaporator Hose (1) - Remove
- Air Conditioning Compressor and Condenser Hose Seal (5) - Remove and DISCARD
Air Conditioning Refrigerant Heat Exchanger Nut (1) @Battery Tray - Remove
Air Conditioning Evaporator Thermal Expansion Valve Hose Nut (1) - Remove
- Air Conditioning Refrigerant Heat Exchanger (2) - Remove
- Air Conditioning Evaporator Thermal Expansion Valve Seal - Large (3) - Remove and DISCARD
- Air Conditioning Evaporator Thermal Expansion Valve Seal - Small (4) - Remove and DISCARD
- Remove retainers as needed.
Battery Tray Bolt (1) - Remove [7x]
Battery Tray (1) - Remove
Exhaust Gas Recirculation Temperature Sensor (2) - Remove and position aside
Turbocharger Heat Shield Bolt (1) - Remove [2x]
- Turbocharger Heat Shield Nut (2) - Remove
Turbocharger Heat Shield (1) - Remove
Catalytic Converter Clamp (1) - Loosen
- Nitrogen Oxides Sensor - Remove and position aside
Exhaust Temperature Sensor - Position 1 (1) - Remove and position aside
Exhaust Temperature Sensor - Position 2 (1) - Remove and position aside
Emission Reduction Fluid Exhaust Front Pipe Injector Supply Pipe Insulator (1) - Remove
Emission Reduction Fluid Injector Clamp (1) - Remove and DISCARD
- Reductant Fluid Injector (2) - Reposition
- Exhaust System Front Gasket (3) - Remove and DISCARD
- Clean the exhaust mounting flange and injector mounting surfaces to remove any soot or emission reduction fluid deposits.
- Front Wheelhouse Liner-Right Side (3) - Remove - Front Wheelhouse Liner Replacement
- Drain the cooling system. Cooling System Draining and Filling (Static LM2) , or Cooling System Draining and Filling (GE 47716 LM2)
Exhaust Temperature Sensor - Position 3 (1) - Remove and position aside
Using a suitable tool, remove the position 2 nitrogen oxides sensor (1) from the nitrogen oxides catalytic converter.
Using a suitable tool, remove the position 3 nitrogen oxides sensor (1) from the nitrogen oxides catalytic converter.
Using a suitable tool, remove the exhaust particulate sensor (1) from the nitrogen oxides catalytic converter.
Exhaust Pipe Clamp (1) - Loosen
Exhaust Front Pipe Nut (1) - Remove [2x]
Catalytic Converter Brace Bracket Nut (1) - Remove [2x]
- Wiring Harness Retainer (2) @Catalytic Converter Brace Bracket (3) - Remove
- Catalytic Converter Brace Bracket (3) - Remove
Exhaust Front Pipe Nut (1) - Remove [2x]
Nitrogen Oxides Catalytic Converter (1) - Remove
- Exhaust System Front Gasket (2) - Remove and DISCARD
Electrical Connector (1) @Exhaust Back Pressure Valve - Disconnect
- Disconnect wiring harness retainers, as required.
Exhaust Gas Recirculation Valve Cooling Return Pipe Bolt (1) - Remove [2x]
- Exhaust Gas Recirculation Valve Cooling Return Pipe (2) - Remove
- Turbocharger Coolant Feed and Return Pipe Gasket (3) - Remove and DISCARD
Catalytic Converter Nut (1) - Remove [3x]
Exhaust Back Pressure Valve (1) - Remove
- Exhaust Gas Recirculation Valve Inlet Gasket (2) - Remove and DISCARD
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
Hose Clamp (1) - Disengage [4x] - Hose Clamp Replacement Guidelines - Spring Type
- Exhaust Gas Recirculation Coolant Return Pipe (2) @Exhaust Gas Recirculation Cooler Inlet Pipe - Remove
- Heater Inlet Hose (3) @Exhaust Gas Recirculation Cooler Inlet Pipe - Remove
- Exhaust Gas Recirculation Cooler Outlet Pipe (4) @Exhaust Gas Recirculation Cooler Inlet Pipe - Remove
- Exhaust Gas Recirculation Cooler Inlet Pipe (5) @Exhaust Gas Recirculation Cooler Inlet Pipe - Remove
Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Thermostat Bypass Hose (2) @Exhaust Gas Recirculation Cooler Inlet Pipe - Remove
Hose Clamp (1) - Disengage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Exhaust Gas Recirculation Valve Cooling Return Hose (3) @Exhaust Gas Recirculation Cooler Inlet Pipe - Remove
- Turbocharger Coolant Feed and Return Pipe (4) @Exhaust Gas Recirculation Cooler Inlet Pipe - Remove
Exhaust Gas Recirculation Pipe Bracket Bolt (1) - Remove [2x]
Exhaust Gas Recirculation Cooler Inlet Pipe (1) - Remove
Remove the 3 rear engine wiring harness channel nuts (1).
- Position the rear engine wiring harness channel (2) out of the way.
Remove the 2 exhaust pressure differential sensor bracket studs (1) and reposition the exhaust pressure differential bracket (2).
Disengage the exhaust pressure differential sensor hose clamp (1) and remove the exhaust pressure differential sensor from the exhaust gas recirculation valve hose. Hose Clamp Replacement Guidelines - Spring Type
Disengage the exhaust pressure differential sensor hose clamp (1) and remove the exhaust pressure differential sensor at the exhaust gas recirculation cooler. Hose Clamp Replacement Guidelines - Spring Type
Disengage the 2 exhaust pressure differential sensor hose clamp (1) and remove the 2 exhaust pressure differential sensor hoses at the exhaust gas recirculation cooler. Hose Clamp Replacement Guidelines - Spring Type
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 Valve Bracket Nut (1) - Remove
- Heater Inlet Hose Bracket (2) - Reposition
Exhaust Gas Recirculation Pipe Bolt (1) - Remove [2x]
Remove the exhaust gas recirculation valve (1) with the exhaust gas recirculation valve hose.
- Exhaust Gas Recirculation Valve Cooler Gasket (2) - Remove and DISCARD
Exhaust Gas Recirculation Cooler Inlet Pipe Bolt (1) - Remove [4x]
- Exhaust Gas Recirculation Pipe (2) - Remove
- Exhaust Gas Recirculation Cooler Inlet Pipe Gasket- Lower (3) Remove and DISCARD
- Exhaust Gas Recirculation Cooler Inlet Pipe Gasket- Upper (4) Remove and DISCARD
Disconnect the electrical connector at exhaust gas recirculation cooler.
- Remove the 4 exhaust gas recirculation cooler nuts (1).
Remove the exhaust gas recirculation cooler (1).
{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]
Fuel Heater Inlet and Outlet Nut (1) - Remove
- Fuel Cooler Coolant Cooler Inlet Hose - Reposition
Catalytic Converter Brace Bracket Nut (1) - Loosen [2x]
- Reposition hoses and wiring harness as needed.
Nitrogen Oxides Catalytic Converter (1) - Remove
- Catalytic Converter Clamp (2) - Remove and DISCARD
- Catalytic Converter Gasket (3) - Remove and DISCARD
Catalytic Converter Brace Bracket Bolt (2) - Remove [2x]
- Catalytic Converter Brace Bracket (1) - Remove
- NOTE:
Some components not shown for graphic clarity.
Engine Wiring Harness Bracket Nut (1) - Remove [2x]
- Engine Wiring Harness Bracket Bolt (2) - Remove
- Reposition the engine wiring harness channel (3) away from the front of the engine.
Remove the fuel injector wiring harness connector (1) from the engine coolant air bleed bracket.
- NOTE:
- Some components not shown for graphic clarity.
- It is not necessary to remove both bolts.
Engine Coolant Air Bleed Pipe Bolt- Right Side Upper (1) - Remove
- NOTE:
It is not necessary to remove both gaskets.
Turbocharger Coolant Feed and Return Pipe Gasket- Right Side Upper (1) - Remove and DISCARD
{If equipped} Engine Wiring Harness Ground Bolt (1) - Remove
- {If equipped} Ground Cable (2) - Position aside
Install the EN-36857 Engine Lift Bracket (1) to the front left side of the cylinder head as shown using the EN-51768 Engine Support Fixture Adaptor Bolt - M8 (2).
Chassis Front Wiring Harness Bracket Bolt- Rear (1) - Remove
- Chassis Wiring Harness Front Bracket Retainer (2) - Remove [2x]
- Chassis Front Wiring Harness Bracket Bolt- Front (3) - Remove
- Remove the positive battery cable retainers from the chassis wiring harness front bracket.
- Chassis Wiring Harness (4) - Reposition
Working through the wheelhouse opening Remove and DISCARD the 3 engine mount frame side bolts (1).
- Raise the engine with a suitable lifting device to remove the engine mount.
Remove and DISCARD the 2 engine mount engine side bolts (1).
- If equipped, disconnect electrical connector at the rear of engine mount.
Engine Mount (1) - Remove
Engine Mount Bracket Bolt (1) - Remove [4x]
- Engine Mount Bracket (2) - Remove
Do not use a prying tool to remove the injector.
After removing the injector, wipe any residual DEF with a clean towel to avoid urea crystal build up at the connection during installation. Urea crystal build-up can result in a future leak.
When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the crankshaft pulley. Lifting the engine in an unapproved manner may cause component damage.
When raising the engine only raise enough to separate the engine mount from the engine mount bracket. Raising any further will require removal of the fan shroud or the exhaust pipe.