Removal Procedure
- Plenum Front Panel Outer Reinforcement - Remove - Plenum Front Panel Outer Reinforcement Removal and Installation
- Drain the cooling system. Cooling System Draining and Filling (Static LM2) , or Cooling System Draining and Filling (GE 47716 LM2)
- Front Wheelhouse Liner- Left Side - Remove - Front Wheelhouse Liner Replacement
Engine Wiring Harness Bracket Nut (1) - Remove [2x]
- Engine Wiring Harness Bracket (2) - Reposition
Oil Level Indicator Tube Stud (1) - Remove
- Clip (2) @Oil Level Indicator Tube - Remove
- 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.
Charge Air Cooler Outlet Air Hose Clamp (1) - Loosen until disengaged [2x]
- Charge Air Cooler Outlet Air Hose (2) - Remove
Disconnect the throttle body electrical connector.
- Throttle Body Bolt (1) - Remove [3x]
- Throttle Body (2) - Remove
- Throttle Body Gasket (3) - Remove and DISCARD
Hood Latch Actuator Bolt (1) - Remove [2x]
- Hood Secondary Latch Release Handle (2) - Remove
Intake Air Baffle Retainer (1) - Remove [9x]
- Intake Air Splash Shield (2) - Remove
Intake Air Duct Retainer (1) - Remove
- Intake Air Duct (2) - Reposition
Air Cleaner Outlet Duct Clamp (1) - Loosen [2x]
- Air Cleaner Outlet Front Duct (2) - Remove
- Disconnect the mass airflow sensor electrical connector.
Air Cleaner Housing Cover Bolt (1) - Remove [3x]
- Air Cleaner Upper Housing (2) - Remove
Electrical Connector (1) @Air Cleaner Lower Housing - Remove
- Remove all retainers from air cleaner lower housing.
Engine Wiring Harness Fuse Block Bracket Bolt (1) - Remove
- Accessory Wiring Junction Block (2) - Reposition
Air Cleaner Nut (1) - Remove
Air Cleaner Lower Housing (1) - Remove
Air Cleaner Outlet Duct Clamp (1) - Loosen
- Air Cleaner Outlet Duct (2) - Remove
Unclip the engine coolant temperature sensor wiring harness (1) from the intake manifold.
Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Exhaust Gas Recirculation Cooler Water Bypass Inlet Hose (2) @Thermostat Bypass Hose - Remove
Engine Coolant Air Bleed Hose Stud (2) - Remove
- Thermostat Bypass Hose (1) - Reposition
Hose Clamp (1) - Disengage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Turbocharger Coolant Return Hose (2) @Exhaust Gas Recirculation Coolant Return Pipe - Remove
- Exhaust Gas Recirculation Coolant Return Pipe (3) @Exhaust Gas Recirculation Coolant Return Pipe - Remove
Thermostat Bypass Pipe Bolt (3) - Remove
- Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Wiring Harness Retainer (2) @Exhaust Gas Recirculation Coolant Return Pipe - Remove
- Exhaust Gas Recirculation Coolant Return Pipe (4) - Remove
Disconnect and unclip the glow plug wiring harness (1) from the intake manifold.
Engine Oil Level Indicator (1) - Remove
Oil Level Indicator Tube Bolt (1) - Remove
- Oil Level Indicator Tube (2) - Remove
Oil Level Indicator Tube Seal (2) - Remove and DISCARD
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
Remove the 3 rear engine wiring harness channel nuts (1).
- Position the rear engine wiring harness channel (2) out of the way.
Remove the engine coolant outlet pipe bracket bolt (1) and position the engine coolant air bleed hose (2) out of the way.
- NOTE:
Note: Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.
Exhaust Gas Recirculation Cooler Bolt (1) - Remove [2x]
Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Turbocharger Coolant Return Hose (2) @Turbocharger Coolant Feed Pipe - Remove
- 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.
- Exhaust Gas Recirculation Outlet Pipe Bolt (2) - Remove
Exhaust Gas Recirculation Outlet Pipe Bolt (1) - Remove [2x]
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).
Engine Wiring Harness Bracket Nut (1) - Remove [2x]
- Engine Wiring Harness Bracket Bolt (2) - Remove
- Disconnect electrical connectors as needed, detach retainer at intake manifold and reposition the engine wiring harness channel (3) away from the front of the engine.
Intake Manifold Insulator Retainer (2) - Remove [2x]
- Intake Manifold Insulator (1) - Remove
Intake Manifold Bolt (2) - Remove [9x]
- Intake Manifold (1) - Remove
- Intake Manifold Gasket (3) - Remove and DISCARD [6x]
With aid of assistant reposition the engine wiring harness and note the routing of oil level indicator tube.