Steps 41-100

Engine - Body On









Removal

41. NOTICE: The coolant hose clamps used on this engine are constant tension worm gear clamps. Standard worm gear clamps cannot be used. Failure to use correct coolant hose clamps can result in hose joint failure.

Loosen the clamp and disconnect the EGR cooler hose.

- Discard the EGR cooler hose clamp.





42. Remove the 2 retaining nuts for the vertical EGR cooler.





43. Remove the bolt and the EGR cooler coolant tube.
- Remove and discard the O-ring seal.





44. Disconnect the coolant hose at the vertical EGR cooler.





45. Disconnect the Exhaust Gas Recirculation Temperature (EGRT) sensor electrical connector.





46. Remove the nut and bolt for the vertical EGR cooler.





47. Remove the vertical EGR cooler stud.
- Remove and discard the gasket.





48. Remove the 5 bolts and the vertical EGR cooler assembly.
- Remove and discard the gasket.





49. Disconnect the retainers for the lower radiator hose.





50. NOTE: Upper radiator hose shown, lower radiator hose similar.

Remove the clips. Remove the upper and lower radiator hoses.





51. Disconnect the filter minder and the Mass Air Flow (MAF) sensor electrical connectors. Disconnect the wire retainer and position aside the wire.





52. NOTE: The Air Cleaner (ACL) is most easily removed by lifting under the ACL outlet pipe end to tilt it upward and separate it from the ACL outlet pipe, then pulling the ACL up and away from the ACL intake pipe.

Loosen the clamp and remove the ACL assembly.





53. Remove the auxiliary air intake from the cowl.





54. Remove the clamp at the crankcase vent oil separator. Loosen the clamp and remove the ACL outlet pipe.
- Discard the clamp on the crankcase vent oil separator.





55. Disconnect the EGR valve and Throttle Body (TB) electrical connectors.





56. Remove the 4 bolts and the intake throttle adapter.
- Remove and discard the press-in-place gasket.





57. Disconnect the vacuum tube from the engine fill hose and remove the engine fill hose. Disconnect the heater hose and position aside.





58. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes.

Remove the 2 banjo bolts and sealing washers at the fuel filter module.

- Discard the sealing washers.





59. Disconnect the pushpin retainer and the LH fuel charging harness electrical connector.





60. Disconnect the fuel temperature sensor electrical connector. Remove the bolt and disconnect the engine wiring harness.





61. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes.

NOTE: The hose will not be completely disconnected until the fuel filter module is removed.

Using a commercially available tool, release the fuel supply hose connector.





62. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes.

Remove the 2 banjo bolts and sealing washers on the fuel cooler.

- Discard the sealing washers.





63. Remove the 3 bolts and the fuel filter module.





64. NOTICE: Do not lean on, pull on or use the turbocharger oil supply tube as a handle or damage to the turbocharger oil supply tube may occur.

NOTE: Use a back-up wrench to prevent the fittings from turning.

Remove the 2 turbocharger oil supply tube banjo bolts and sealing washers.

- Discard the sealing washers.





65. Remove the bolt and the turbocharger oil supply tube.
- Remove and discard the O-ring seal.





66. Remove the oil filter cap and oil filter element.
- Discard the O-ring seal and oil filter element.





67. Remove the 4 bolts and the oil filter housing.





68. Remove the screw and the oil filter return tube.





69. Remove and discard the O-ring seal and gasket.





70. Disconnect the crankcase vent oil separator drain tube.





71. Remove the 4 bolts and the crankcase vent oil separator.
- Remove and discard the press-in-place gasket.





72. Remove the 5 bolts and the turbocharger heat shield.





73. Remove the clamp for the turbocharger exhaust downpipe.
- Disconnect the exhaust downpipe from the turbocharger.

- Discard the clamp and gasket.





74. Remove the 3 bolts for the turbocharger actuator cooler.





75. Remove the 2 bolts for the fuel cooler.





76. Remove the 2 stud bolts for the fuel cooler.





77. Remove the 2 retaining nuts for the fuel cooler.





78. Remove the 3 bolts for the coolant expansion tank. Position aside the turbocharger actuator cooler, fuel cooler and coolant expansion tank.





79. Remove the fuel cooler bracket.





80. Disconnect the turbocharger actuator electrical connector and pushpin retainer.





81. NOTE: Rear bolts shown, front bolts similar.

Remove the 4 bolts for the turbocharger crossover tube. Remove the front fuel cooler bracket.





82. Disconnect the Exhaust Pressure (EP) sensor electrical connector and retaining clip.





83. Disconnect the EP sensor tube from the EGR-OC pipe.





84. Remove the nut and the EP tube assembly.





85. Remove the fitting for the EP tube assembly.





86. Remove and discard the 2 upper bolts for the EGR-OC pipe.
- Remove and discard the gasket.





87. Remove and discard the 2 lower bolts for the EGR-OC pipe.
- Remove and discard the gasket.





88. Remove and discard the 2 mounting bolts for the EGR-OC pipe.
- Position the EGR-OC pipe as needed to access the bolts for the turbocharger inlet pipes.





89. NOTE: It will be necessary to position the EGR-OC pipe to access the bolts as needed.

Remove the 6 bolts and bracket for the turbocharger inlet pipes.
- Discard the bolts and gaskets.





90. Remove the 2 bolts and 2 hold downs for the turbocharger.





91. Install the Turbocharger Lifting Bracket.
- Tighten to 20 Nm (177 lb-in).





92. NOTICE: Failure to use the Turbocharger Lifting Bracket during removal, handling or installation of the turbocharger could result in damage to the low pressure-to-high pressure turbocharger seal.

NOTICE: Make sure the turbocharger assembly is kept level with the engine during removal or installation. Failure to follow this instruction may result in damage to the high-pressure oil drain tube.

NOTE: Use care when removing the turbocharger. The crossover tube should not be removed, it has one-time-use seals.

Using the Heavy Duty Floor Crane, remove the turbocharger assembly.

93. Remove the turbocharger drain tubes.

1. Remove and discard the low-pressure drain tube.

2. Remove the high-pressure drain tube.

- Remove and discard the O-ring seals.





Vehicles with automatic transmission

94. Remove the retaining nut and the transmission indicator and tube.





All vehicles

95. Disconnect the EGRT sensor electrical connector.





96. Remove the RH splash shield.

97. Remove the EGRT sensor.





98. Remove the nut and position the battery cable bracket aside.





99. Remove the cover for the starter terminals.





100. Remove the 2 retaining nuts for the starter solenoid wiring. Position the starter wiring aside.