Removal Procedure
- Relieve the fuel system pressure. Fuel Pressure Relief
- Drain the cooling system. Cooling System Draining and Filling (L3B Static Fill) , or Cooling System Draining and Filling (L3B GE 47716)
- Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
Oil Level Indicator (1) - Remove
Oil Level Indicator Tube Bracket Bolt (1) - Remove
Oil Level Indicator Tube (1) - Remove
- Inspect the oil level indicator tube seal (2) and replace as necessary.
- Remove the oil fill cap.
Intake Manifold Cover Bolt (1) - Remove [2x]
- Lift up on the front of the intake manifold cover (2).
Intake Manifold Cover (1) @ Upper Intake Manifold Bracket (2) - Remove
Intake Manifold Cover Bolt (1) - Remove
Intake Manifold Cover Insulator (1) - Remove
Fuel Feed Pipe (1) - Disconnect and reposition
- Evaporative Emission Pipe (2) - Disconnect and reposition
Evaporative Emission Canister Purge Tube (1) - Disconnect and reposition
- Retainer (2) - Unclip [3x]
- Radiator Surge Tank Inlet Hose (3) - Reposition
Throttle Body Electrical Connector (1) - Disconnect
Engine Wiring Harness Bolt (1) - Remove
- Electrical Connector (2) - Disconnect [2x]
- Retainer (3) - Unclip [4x]
- Engine Wiring Harness (4) - Reposition
Evaporative Emission Canister Purge Pump Bolt (1) - Remove [3x]
- Evaporative Emission Canister Purge Pump (2) - Remove
Intake Manifold Cover Bolt (1) - Remove [2x]
- Intake Manifold Cover Stud (2) - Remove [3x]
Upper Intake Manifold Cover (1) - Remove
Retainer Spring (1) - Release
- Charge Air Cooler Outlet Air Tube (2) @ Throttle Body (3) - Remove
Retainer (1) - Unclip
Intake Manifold Bolt (1) - Remove [6x]
Intake Manifold (1) - Remove
Crankcase Vent Passage Seal (4) - Remove and DISCARD
- Intake Manifold Gasket (3) - Remove and DISCARD [4x]
Hose Clamp (1) - Disengage [3x] - Hose Clamp Replacement Guidelines - Spring Type
- Thermostat Bypass Pipe (2) @ Engine Coolant Flow Control Valve - Remove
- Radiator Inlet Hose (3) @ Engine Coolant Flow Control Valve - Remove
- Engine Oil Cooler Coolant Inlet Hose (4) @ Engine Coolant Flow Control Valve - Remove
Hose Clamp (1) - Disengage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Exhaust Manifold Outlet Pipe (2) @ Engine Coolant Flow Control Valve - Remove
- Engine Coolant Thermostat Housing Inlet Pipe (3) @ Engine Coolant Flow Control Valve - Remove
Electrical Connector (1) @ Engine Coolant Temperature Sensor - Disconnect
- Electrical Connector (2) @ Engine Coolant Flow Control Valve - Disconnect [2x]
Engine Coolant Flow Control Valve Bolt (1) - Remove [5x]
Engine Coolant Flow Control Valve (1) - Remove
- Engine Coolant Flow Control Valve Seal (2) - Remove and DISCARD
Nut @ Fuel Feed Intermediate Pipe (1) - Loosen [2x]
Fuel Injection Fuel Feed Pipe Bracket Bolt (1) - Remove
- Fuel Feed Intermediate Pipe (2) - Remove and DISCARD
- WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise canceling 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.
Fuel Injection Fuel Rail Noise Shield (1) - Remove
Electrical Connector (1) - Disconnect
- Fuel Injection Fuel Rail Bolt (2) - Remove [4x]
Disconnect the knock sensor electrical connectors (1).
- In some cases, the fuel injectors may be difficult to remove because of heavy carbon build-up or other factors. DO NOT use excessive force with the removal tool. If injectors are difficult to remove, apply solvent to the base of the injector bores, and allow adequate soaking time, to loosen the fuel injectors.
- Pull the fuel rail and injectors as an assembly.
- To prevent material from entering the combustions chambers make sure the area around each injector is clean and free of debris before the injectors are removed from the injector bores.
- Install two sets of EN-49248 Injector Rail Assembly Remover (2).
- Turn both handles on the EN-49248 Injector Rail Assembly Remover to disengage the fuel injection fuel rail.
- Direct Fuel Injection Fuel Rail (3) - Remove
Remove and DISCARD the fuel injector wiring harness tie straps (1).
- Disconnect and remove the fuel injector wiring harness (2).
- CAUTION:
Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method.
Fuel Injector Retainer (1) - Remove [4x]
- Direct Fuel Injector (2) - Remove [4x]
Fuel Injector Bushing (1) - Remove and DISCARD
- Fuel Injector Nozzle Housing Seal (2) - Remove and DISCARD