Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Removal Procedure
- Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
- Drain the cooling system. Cooling System Draining and Filling (GE 47716)
Oil Filler Cap - Remove
Intake Manifold Cover (1) - Remove
- NOTE:
To avoid small parts like bolts or retainers fallen into the engine, install the oil filler cap.
Oil Filler Cap (1) - Install
Positive Crankcase Ventilation Fresh Air Tube (1) @ Air Cleaner Outlet Duct - Disconnect - Plastic Collar Quick Connect Fitting Service
Turbocharger Outlet Duct Front Clamp (1) - Loosen
- Air Cleaner Outlet Duct Clamp (5) - Loosen
- Air Cleaner Outlet Duct Bolt (2) - Remove [2x]
- Air Cleaner Outlet Duct Nut (3) - Remove
- Air Cleaner Outlet Duct (4) - Remove
Charge Air Cooler Bolt (1) - Remove [4x]
Charge Air Cooler Outlet Air Hose Clamp (1) - Loosen [2x]
- Charge Air Cooler Coolant Hose Retainer (2) - Disengage [2x]
- Charge Air Cooler Coolant Hose (3) - Reposition [2x]
- Charge Air Cooler Inlet Air Hose Clamp (4) - Loosen
- Disconnect the electrical connector. (5)
Charge Air Cooler (1) - Remove
Charge Air Cooler Bracket Bolt (1) - Remove [4x]
Charge Air Cooler Bracket (1) - Remove
Charge Air Cooler Inlet Air Hose Clamp Nut (1) - Remove
- Charge Air Cooler Coolant Hose (2) - Reposition
Release the Hose retainers (1) as necessary.
Release the Hose retainers (1) as necessary.
Intake Manifold Cover Bolt (1) - Remove [3x]
- Oil Level Indicator Tube Bracket Bolt (2) - Remove
- Oil Level Indicator - Reposition
- Disconnect the electrical connectors and release the wiring harness retainers as necessary.
Intake Manifold Cover (1) - Remove
Intake Manifold Bolt (2) - Remove [5x]
- Intake Manifold (1) - Remove
Intake Manifold Gasket @ Intake Manifold (1) - Remove and DISCARD
Disconnect the electrical connectors and reposition the wiring harness as necessary. (1)
Radiator Inlet Hose (2) - Remove
Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Heater Inlet Pipe (2) - Remove
Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Automatic Transmission Fluid Cooling Heat Exchanger Inlet Hose (2) - Remove
Hose Clamp (2) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Engine Oil Cooler Coolant Inlet Hose (1) - Remove
Disconnect the electrical connectors and reposition the wiring harness as necessary. (1)
Engine Coolant Flow Control Valve Bolt (1) - Loosen until disengaged [2x]
Engine Coolant Flow Control Valve Bolt (1) - Loosen until disengaged [3x]
Engine Coolant Flow Control Valve (1) - Remove
Water Outlet Seal (1) - Remove and DISCARD
- Clean and inspect all mating surfaces.
NO RELATED
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.