Removal Procedure
- Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
- Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
- Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
- Loosen the charged air cooler outlet duct clamp (1).
- Remove the charged air cooler outlet duct .
- Loosen the charged air cooler inlet duct to turbocharger clamp (1).
- Remove the charged air cooler inlet duct from the turbocharger.
- Remove the engine wiring harness. Refer to Engine Wiring Harness Assembly Replacement .
- Remove the water outlet tube. Refer to Water Outlet Tube Replacement in Engine Cooling.
- Disconnect the fuel lines from the chassis pipes. Refer to Metal Collar Quick Connect Fitting Service .
- Remove the fuel feed front pipe bracket nut.
- Remove the fuel feed front pipe (1).
- Remove the fuel injection pump to junction block fuel feed front pipe.
- Remove the fuel rail feed pipe bracket
- Remove the fuel rail feed pipe from junction block.
- Remove the fuel rail feed pipe from right fuel rail.
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.
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.
Installation Procedure
- Install the fuel rail feed pipe to the right fuel rail.
- Install the fuel rail feed pipe to the junction block
- Install the fuel rail feed pipe bracket
- Install the fuel injection pump to junction block fuel feed front pipe.
- Remove the fuel feed front pipe (1).
- Remove the fuel feed front pipe bracket nut.
- Connect the fuel lines to the chassis pipes. Refer to Metal Collar Quick Connect Fitting Service .
- Install the water outlet tube. Refer to Water Outlet Tube Replacement in Engine Cooling.
- Install the engine wiring harness. Refer to Engine Wiring Harness Assembly Replacement .
- Install the charged air cooler inlet duct to turbocharger.
- Align the mark on the duct (2) with the mark on the turbocharger.
- Position the clamp (1) as shown for proper clearance.
- Install the charged air cooler outlet duct to the intake.
- Align the mark on the duct (3) with the mark on the turbocharger.
- Position the clamp (1) as shown for proper clearance.
- Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
- Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
- Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
Tighten
Tighten the fittings to 41 N·m (30 lb ft).
Tighten
Tighten the fittings to 41 N·m (30 lb ft).
Tighten
Tighten the nut to 8 N·m (70 lb in).
Tighten
Tighten the clamp to 6 N·m (53 lb in).
Tighten
Tighten the clamp to 6 N·m (53 lb in).
