Removal Procedure
- Relieve the fuel system pressure. Fuel Pressure Relief
- Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
Oil Filler Cap (1) - Remove
- Oil Filler Cap Seal (2) - Remove
- Intake Manifold Cover (3) - Remove
Air Cleaner Clamp (1) - Loosen
- Air Cleaner Outlet Duct Clamp (2) - Loosen
Air Cleaner Outlet Front Duct (1) - Remove
Intake Air Duct Retainer (1) - Remove [2x]
- Release the 2 retainer tabs (arrows) to remove the intake air duct.
Intake Air Duct (1) - Remove
Turbocharger Wastegate Actuator Vacuum Control Solenoid Valve Filter Hose (1) @ Air Cleaner Assembly (2) - Remove
Electrical Connector (1) - Disconnect
- Wiring Harness Retainer (2) - Remove
Air Cleaner Clamp (1) - Loosen
- Air Cleaner Outlet Front Duct (2) @ Air Cleaner Assembly (3) - Remove
Air Cleaner Assembly (1) - Remove
Wiring Harness Retainer (1) - Remove [3x]
- Clip (2) - Remove [2x]
Charge Air Cooler Inlet Air Hose Clamp Nut (1) - Remove
Charge Air Cooler Inlet Air Hose Retainer Spring (1) - Release
- Charge Air Cooler Inlet Air Hose @ Turbocharger Assembly - Position aside
Fuel Feed Front Pipe (1) @ Fuel Pump (2) - Disconnect - Metal Collar Quick Connect Fitting Service
Fuel Feed Front Pipe (1) @ Fuel Feed Pipe - Underbody (2) - Disconnect - Metal Collar Quick Connect Fitting Service
Fuel Feed Front Pipe (1) @ Vehicle - Remove
Evaporative Emission Pipe-Underbody (1) @ Evaporative Emission Canister Purge Pump (2) - Disconnect - Plastic Collar Quick Connect Fitting Service
Evaporative Emission Pipe-Underbody (1) @ Retainer (2) - Remove [3x]
- Evaporative Emission Pipe-Underbody (1) Position aside
Wiring Harness Retainer (1) - Release [2x]
- Engine Wiring Harness (2) - Position aside
Evaporative Emission Canister Purge Tube Clip (1) - Remove [3x]
Evaporative Emission Canister Purge Tube (1) @ Evaporative Emission Canister Purge Solenoid Valve (2) - Disconnect - Plastic Collar Quick Connect Fitting Service
Evaporative Emission Canister Purge Tube (1) @ Evaporative Emission Canister Purge Pump (2) - Disconnect - Plastic Collar Quick Connect Fitting Service
Evaporative Emission Canister Purge Tube (1) - Remove
Disconnect the electrical connector. (1)
- Positive Crankcase Ventilation Vacuum Hose Clamp (2) - Disengage [2x] - Hose Clamp Replacement Guidelines - Spring Type
Positive Crankcase Ventilation Vacuum Hose (1) - Remove
Positive Crankcase Ventilation Vacuum Hose Clamp @ Camshaft Cover (1) - Disengage
- Positive Crankcase Ventilation Vacuum Hose (2) - Remove
Retainer (1) - Disconnect [8x]
- Turbocharger Coolant Return Pipe Bracket Bolt (2) - Remove [2x]
- Turbocharger Coolant Return Pipe Bracket (3) - Position aside
- Electrical Connector (4) - Disconnect [8x]
Ignition Coil Bolt (1) - Remove [6x]
- Ignition Coil (2) - Remove [3x]
Oil Level Indicator - Remove
Camshaft Cover Bolt (1) - Remove [17x]
- NOTE:
Camshaft Cover and Camshaft Cover Heat Shield as an assembly.
Camshaft Cover (1) - Remove
- Camshaft Cover Gasket (3) - Remove and DISCARD
Turbocharger Wastegate Regulator Solenoid Valve Bolt (1) - Remove [2x]
- Turbocharger Wastegate Regulator Solenoid Valve (2) - Remove
Retainer (1) - Disconnect [5x]
Stud (1) - Remove
- Ground Cable (2) - Position aside
Fuel Pump Shield Bolt (1) - Remove [3x]
- Fuel Pump Cover (2) - Remove
Fuel Feed Intermediate Pipe Nut (1) - Loosen [2x]
- Fuel Feed Intermediate Pipe Bolt (2) - Remove
- Fuel Feed Intermediate Pipe (3) - Remove and DISCARD
Electrical Connector (1) - Disconnect
Fuel Injection Fuel Rail Bolt (1) - Remove [4x]
Fuel Injector Retainer (1) - Remove and DISCARD
Cable Tie (1) - Remove and DISCARD [4x]
Fuel Injector Electrical Connector (1) - Disconnect [3x]
Direct Fuel Injection Fuel Rail (1) - Remove
EN-52433 Injector Remover (2) @ EN-51146-1-3 slide hammer (1) - Assemble
- EN-52433 Injector Remover (2) @ Fuel Injector (3) - Install
- Direct Fuel Injector (3) - Remove [3x] - Use EN-51146-1-3 slide hammer
- Remove the special tools.
Fuel Injector Seal (1) - Remove and DISCARD [3x]
- Fuel Injector Seal Retainer - White (2) - Remove [3x]
- Fuel Injector Seal Retainer - Red (3) - Remove [3x]
- Combustion Fuel Injector Seal (4) - Remove and DISCARD [3x]
Inspect and replace as necessary.
Direct Fuel Injection Fuel Rail Cleaning and Inspection
- For this operation the direct fuel injection fuel rail, the direct fuel injector and the fuel injector seals are removed.
Use the EN-47909 Injector Bore and Sleeve Cleaning Kit (1) to clean the direct fuel injector bores.
- NOTE:
Do NOT soak or submerge the fuel rail or injectors in solvent.
Clean the exterior of the direct fuel injection fuel rail and direct fuel injectors in solvent.
- Inspect the fuel injection fuel rail fuel pressure sensor (1) for damage.
- If replacing, dry the fuel injection fuel rail fuel pressure sensor bore in the fuel rail with a lint free cloth.
- The bore should be free of fuel, debris, and burrs.
- Inspect the direct fuel injection fuel rail and components for the following conditions:
- Damage, debris, or restrictions to the fuel rail
- Damage, debris, or restrictions to the fuel ports in the fuel rail
- Damage to the mounting area for the fuel rail
- Damage to the fuel rail mounting bolts
- Damage to the threads on the fuel rail fuel feed fitting
Inspect the direct fuel injectors for the following conditions:
- Damage to the fuel injector connector (1)
- Damage to the fuel injector
- Damage to the fuel injector housing (3)
- Damage to the fuel injector head adapter (5)
- Damage to the fuel injector combustion sealing surfaces (4).
- Damage to the fuel injector sealing surfaces (2).
- Replace the direct fuel injection fuel rail or direct fuel injector if any damage is found. Do not attempt to repair a fuel rail or injector.
- Clean the fuel injector shaft and fuel injector sealing surfaces (2, 4) from gasoline exhaust particulates and sealing deposit with a brass brush and a lint free cloth.
- Repeat the fuel injector cleaning and inspection process for all 3 fuel injectors.
Clean the fuel injectors with a copper brush and a lint free cloth in the direction of the injector opening. Do not contaminate the opening. Contamination of the injector opening can lead to a fuel injection system malfunction.