Removal Procedure
- Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
- Drain the cooling system. Refer to Cooling System Draining and Filling .
- Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
- Loosen the charged air cooler inlet duct connector to turbocharger clamp (1).
- Remove the charged air cooler inlet duct connector (4) from the turbocharger.
- Remove the battery cable to generator nut.
- If equipped, remove the battery cable to the auxiliary generator.
- Remove the battery cable harness clip from the bracket.
- Remove the battery cable junction block bolt (1) from the power steering pump.
- Move and secure the battery cables out of the way.
- Disconnect the fuel lines. Refer to Metal Collar Quick Connect Fitting Service .
- Remove the fuel hose bracket nut.
- Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors.
- Open the harness clip (2).
- Remove the main engine electrical harness connectors.
- Remove the main engine electrical harness connector hold down bolts.
- Remove the main electrical connector harness bracket bolts.
- Remove the main electrical connector harness bracket.
- Remove the water outlet tube. Refer to Water Outlet Tube Replacement .
- Remove the auxiliary generator, if equipped. Refer to Auxiliary Generator Replacement .
- Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement .
- Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris.
- Spray lithium grease between the fuel injector line and fittings to assist in containing any debris during removal. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.
- Remove the left fuel injector pipes.
- Remove the upper valve rocker arm cover bolts.
- Remove the upper valve rocker arm cover.
- Remove the upper valve rocker arm cover gasket.
- Inspect the upper valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket.
- If required, clean and inspect the upper valve rocker arm cover. Refer to Valve Rocker Arm Cover Cleaning and Inspection - Upper .
Important: After removing the charged air cooler duct, cover the turbocharger opening with tape in order to prevent entry of objects.
Important: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
Notice: DO NOT use compressed air to clean debris from the fuel injector inlet after the fuel line is removed. Using compressed air can allow debris to enter the fuel injector inlet and damage the fuel injector.
Installation Procedure
- Install the valve rocker arm cover gasket.
- Install the upper valve rocker arm cover.
- Install the upper valve rocker arm cover bolts.
- Tighten the upper valve rocker arm cover bolts in the sequence shown.
- Install the left fuel injector pipes.
- Install the water outlet tube. Refer to Water Outlet Tube Replacement .
- Install the auxiliary generator, if equipped. Refer to Auxiliary Generator Replacement .
- Install the PCV hose/pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement .
- Install the main electrical connector harness bracket.
- Install the main electrical connector harness bracket bolts.
- Install the main engine electrical harness connector hold down bolts.
- Connect the main engine electrical harness connectors.
- Push down on the latches (1) in order to connect the connectors.
- Close the harness clip (2).
- Connect the fuel lines. Refer to Metal Collar Quick Connect Fitting Service .
- Install the fuel hose bracket nut.
- Position the generator positive cable.
- Install the generator positive cable in the clip on the engine front cover.
- Install the generator positive cable and nut.
- Install the positive battery cable junction block bracket and bolt (1) to the power steering pump.
- Remove the tape from the turbocharger openings.
- Install the charged air cooler inlet duct connector (4) to the turbocharger.
- Tighten the charged air cooler inlet duct connector to turbocharger clamp (1).
- Fill the cooling system. Refer to Cooling System Draining and Filling .
- Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
- Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
Notice: Refer to Fastener Notice in the Preface section.
Tighten
Tighten the bolts to 8 N·m (71 lb in).
Notice: Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak.
Tighten
Tighten the pipes to 41 N·m (30 lb ft).
Tighten
Tighten the bolts to 21 N·m (15 lb ft).
Tighten
Tighten the bolts to 10 N·m (89 lb in).
Tighten
Tighten the nut to 21 N·m (15 lb ft).
Tighten
Tighten the nut to 9 N·m (80 lb in).
Tighten
Tighten the bolt to 9 N·m (80 lb in).
Important: Lubricate the end of the duct prior to installation.
Tighten
Tighten the clamp to 6 N·m (53 lb in).
