Part 3

Engine














WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

WARNING: Clean all fuel residue from the engine compartment. If not removed, fuel residue may ignite when the engine is returned to operation. Failure to follow this instruction may result in serious personal injury.

NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

NOTICE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

NOTE: A clean working environment is essential to prevent dirt or foreign material contamination into the fuel rails.

NOTE: For additional information, refer to the exploded view under the Assembly procedure.

61. Remove the 2 bolts and the upper LH turbocharger bracket-to-cylinder block bracket.





62. Remove the 3 LH turbocharger-to-exhaust manifold bolts and turbocharger.
- Discard the gasket and bolts.






63. Remove the 8 LH exhaust manifold nuts (6 shown) and the exhaust manifold.
- Discard the exhaust manifold gasket and nuts.






64. Clean and inspect the LH exhaust manifold.

65. Remove and discard the 8 LH exhaust manifold studs.





66. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.

Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.


67. Remove the LH coolant tube bracket-to-cylinder head nut.





68. Remove the nut and the heat shield.





69. Remove the wiring harness retainer stud bolt.





70. Remove the wiring harness grommet.





71. Disconnect the Crankshaft Position (CKP) sensor electrical connector.





72. Remove the bolt and the CKP (Crankshaft Position) sensor.





73. Remove the 5 bolts and the 2 upper RH exhaust manifold heat shields.





74. Disconnect the turbocharger wastegate regulating valve hose from the RH turbocharger assembly.





75. Remove the 2 bolts and the RH turbocharger oil return tube from the RH turbocharger.
- Remove and discard the gasket.






76. Remove the RH turbocharger oil return tube from the cylinder block.
- Discard the 2 O-ring seals.






77. Remove the RH oil supply tube secondary latch.





78. Using the Spring Lock Coupling Disconnect Tool, remove the RH oil supply tube from the quick connect fitting.
- Inspect and if necessary, replace the quick connect fitting.






79. Remove the 2 coolant tube banjo bolts and the RH turbocharger coolant tubes.
- Discard the sealing washers.






80. Remove the 3 bolts and the upper turbocharger-to-cylinder block bracket.





81. Remove the 3 exhaust manifold-to-turbocharger bolts and the turbocharger assembly.
- Discard the gasket and bolts.






82. Remove the RH turbocharger oil supply tube banjo bolt.
- Discard the sealing washer.

- Discard the oil supply tube filter.






83. Remove the 8 nuts and the RH exhaust manifold.
- Discard the nuts and exhaust manifold gaskets.






84. Clean and inspect the RH exhaust manifold.

85. Remove and discard the 8 RH exhaust manifold studs.





86. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.

Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.


87. Remove the 2 bolts and the RH engine lifting eye.





88. Remove the RH coolant tube bracket-to-cylinder head bolt and the coolant tube assembly.





89. Remove the pin-type retainer and the cover.





90. Detach the wiring harness retainer from the rear of the LH cylinder head.





91. Remove the LH cylinder block drain plug.
- Allow coolant to drain from the cylinder block.






92. Remove the RH cylinder block drain plug or, if equipped, the block heater.
- Allow coolant to drain from the cylinder block.






93. Remove the nut for the high pressure fuel tube from the LH valve cover stud bolt and disconnect the Fuel Rail Pressure (FRP) sensor electrical connector.





94. NOTE: To release the fuel pressure in the high pressure fuel tube, wrap the flare nuts with a shop towel to absorb any residual fuel pressure during the loosening of the flare nuts.
Remove the high pressure fuel tube flare nut from the fuel injection pump. Remove the 2 high pressure fuel tube flare nuts from the fuel rails and remove the high pressure fuel tube assembly.






95. Remove the 2 bolts and the fuel injection pump.





96. Remove the fuel injection pump mounting plate.





97. NOTE: Valve cover is removed for clarity.
Remove the fuel injection pump roller tappet.

- Inspect the fuel injection pump roller tappet.






98. NOTICE: It is very important to note the routing of the wiring harness on the fuel rails and index-mark the locations of the tie straps prior to removal or damage may occur to the wire harnesses during installation. The illustration details the correct wire harness routing and tie strap positioning for installation.

NOTE: Use compressed air to remove any dirt or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors.
Carefully cut and remove the fuel rail wire harness tie straps.






99. NOTICE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.

NOTE: When removing the fuel rails, the fuel injectors may remain in the fuel rails but normally remain lodged in the cylinder heads and require the use of a Fuel Injector Remover to extract.
Remove the 6 bolts and the LH fuel rail.






100. Remove the 6 bolts and the RH fuel rail.