• Exhaust Gas Recirculation Cooler Inlet Pipe Gasket
• Exhaust Gas Recirculation Pipe Seal
• Exhaust System Front Gasket
• Fuel Injection Pump Bolt
• Fuel Pump Access Hole Cover Seal
• High Pressure Diesel Fuel Feed to Rail Pipe[2x]
• Transfer Case Adapter Gasket
• Transfer Case Front Output Shaft Boot Clamp[2x]
• Transmission Fluid Cooler Pipe Seal[2x]
• Transmission Fluid Cooler Seal

• EN-45059 Angle Meter
• EN-52448 High Pressure Fuel Pump Tool

Equivalent regional tools:Special Tools

1. Turn OFF the engine for 30 seconds before proceeding. This will purge the fuel pressure from the complete fuel system.



2. Oil Filler Cap»Remove
3. Intake Manifold Cover Bolt(1)»Remove
4. Intake Manifold Cover(2)»Remove
5. Install the oil filler cap after removal of the intake manifold cover to prevent debris from falling into the engine.



6. Air Cleaner Outlet Duct Clamp(1)»Loosen[2x]
7. Air Cleaner Outlet Front Duct(2)»Remove
8. Plenum Front Panel Outer Reinforcement»Remove—Plenum Front Panel Outer Reinforcement Removal and Installation



9. Air Cleaner Outlet Duct Clamp(1)»Loosen
10. Air Cleaner Outlet Duct(2)»Remove



11. Remove the 3 rear engine wiring harness channel nuts (1).
12. Position the rear engine wiring harness channel (2) out of the way.



13. Engine Coolant Outlet Pipe Bracket Bolt(1)»Remove



14. Engine Coolant Air Bleed Hose(2)»Reposition




Note: Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.

15. Remove the 2 exhaust gas recirculation cooler bolts (1).



16. Turbocharger Coolant Feed and Return Pipe Bolt(3)»Remove



17. Remove the turbocharger coolant return hose clip (1) and position the turbocharger coolant return hose out of the way.
18. Remove the exhaust gas recirculation pipe bolt (2).



19. Remove the 2 exhaust gas recirculation pipe bolts (1).



20. Remove the exhaust gas recirculation pipe (1).
21. Remove and DISCARD the exhaust gas recirculation pipe seal (2).
22. Remove and DISCARD the exhaust gas recirculation cooler inlet pipe gasket (3).



23. Electrical Connector(1)@Charge Air Cooler»Disconnect[2x]
24. Wiring Harness Retainer(2)@Charge Air Cooler»Remove[3x]



25. Wiring Harness Retainer(4)@Charge Air Cooler»Remove
26. Disconnect the nitrogen oxides sensor electrical connector.



27. Upper Intake Manifold Brace Nut(1)»Remove[3x]
28. Reposition the upper intake manifold bracket (2) with the NOX sensor attached.



29. Charge Air Cooler Outlet Air Hose Clamp (1)»Loosen until disengaged[2x]
30. Charge Air Cooler Outlet Air Hose(2)»Remove



31. Charge Air Cooler Inlet Air Hose Clamp(1)»Loosen until disengaged[2x]
32. Charge Air Cooler Inlet Air Hose(2)»Remove



33. Charge Air Cooler Bolt(1)»Remove[4x]



34. Charge Air Cooler»(1)Reposition



35. Turbocharger Heat Shield Bolt(1)»Remove[2x]
36. Turbocharger Heat Shield Nut(2)»Remove



37. Turbocharger Heat Shield(1)»Reposition



38. Release the retaining spring (1).
39. Intake Manifold Resonator(2)»Remove



40. Turbocharger Bracket Bolt(1)»Remove



41. Engine Wiring Harness Bracket Nut(1)»Remove[2x]
42. Engine Wiring Harness Bracket(3)»Reposition



43. Oil Filler Tube Support Stud(1)»Remove



44. Engine Coolant Air Bleed Hose Clip(1)»Remove



45. Charge Air Cooler Bracket Bolt(1)»Remove[5x]
46. Charge Air Cooler Bracket(2)»Remove



47. Reposition harness, hoses and electrical connectors, as needed.
48. Exhaust Gas Recirculation Pipe Bracket Bolt(1)»Remove
49. Exhaust Gas Recirculation Pipe Bracket(5)»Remove




Danger: The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise canceling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.

50. Camshaft Housing Cover Insulator(1)»Remove
51. Front Wheelhouse Liner-Left Side»Remove—Front Wheelhouse Liner Replacement



52. Remove the 2 high pressure diesel fuel feed to rail pipe bracket bolts (1).
53. Unclip the fuel injector fuel return pipe retainer (2).



54. Disconnect the 2 high pressure diesel fuel feed to rail pipe fittings (1) from the high pressure diesel fuel injection rail.



55. Fuel Feed Pipe Clip Bolt(1)»Remove



56. Fuel Pump Fuel Feed Hose(1)»Disconnect[2x]—Metal Collar Quick Connect Fitting Service
57. Fuel Pump Fuel Feed Hose(1)»Remove



58. Fuel Return Pipe(1)@Diesel Fuel Separator»Disconnect—Metal Collar Quick Connect Fitting Service




Note: Disconnect the fuel injector fuel return pipe at the diesel fuel separator only.

59. Fuel Injector Fuel Return Pipe Clamp (1)»Disengage—Hose Clamp Replacement Guidelines - Spring Type
60. Fuel Injection Fuel Return Pipe (2)»Reposition



61. Disconnect the 2 high pressure diesel fuel feed to rail pipe fittings (1) from the high pressure diesel fuel pump.



62. Remove the 2 high pressure diesel fuel feed to rail pipe bracket bolts (1).



63. Diesel Fuel Separator Bracket Bolt(1)»Remove



64. Diesel Fuel Separator(1)»Disconnect—Metal Collar Quick Connect Fitting Service
65. Diesel Fuel Separator(1)»Remove




Note: Do NOT reuse the high pressure diesel fuel feed pipes.

66. Remove the high pressure diesel fuel feed to rail pipe (2) from the vehicle and DISCARD.
67. Transmission»Remove—Automatic Transmission Removal and Installation



68. Timing Chain Cover Bolt(1)»Remove[2x]
69. Fuel Pump Access Hole Cover(2)»Remove
70. Fuel Pump Access Hole Cover Seal(3)»Remove and DISCARD



71. Install the EN-52448-1 High Pressure Fuel Pump Tool (1) to the fuel injection pump driven sprocket by inserting the 3 dowels into the sprocket holes.

Note: Engine may have to be rotated slightly to align the EN-52448-1 High Pressure Fuel Pump Tool (1). Rotate the engine using the crankshaft balancer until the mounting holes align.

Caution: Refer to Fastener Caution.

72. Tighten the EN-52448-1 High Pressure Fuel Pump Tool (1) to the fuel pump access bolt holes using the previously removed 2 timing chain cover bolts (2). Fastener Specifications



73. Remove and DISCARD the fuel injection pump bolt (1).



74. Mark the high pressure diesel fuel pump shaft and the fuel injection pump driven sprocket at the slot in the shaft (1). This will help with the alignment of the high pressure diesel fuel pump and the fuel injection pump driven sprocket to keep the pump timed with the engine.



75. Disconnect the 2 high pressure diesel fuel pump electrical connectors (1).



76. Reposition hoses and harness, as needed.
77. Disconnect the electrical connectors from the engine coolant temperature sensor and the block heater.
78. Remove the 3 fuel injection pump bolts (1).



79. Install the EN-52448-3 Nut (2) to the fuel injection pump driven sprocket (3).
80. Install the EN-52448-2 Screw (1) to the EN-52448-3 Nut.
81. Press out the fuel injection pump from the fuel injection pump sprocket (3), by screwing in the EN-52448-2 screw (1) into the EN-52448-3 Nut (2).
82. Remove the EN-52448-2 Screw (1).
83. Remove the EN-52448-3 Nut (2) from the fuel injection pump driven sprocket (3).



84. Remove the high pressure diesel fuel pump (1).
85. Remove and DISCARD the fuel injection pump seal (2).

1. Inspect the charge air cooler inlet air hose (2):
1. Use dish soap and water to clean the inside of the charge air cooler inlet air hose (2). Clean the interior of the hose, and allow to completely dry. Ensure any oil residue is removed from the hose internal interface surfaces.
2. Inspect the interior of the charge air cooler inlet air hose (2) for tears or delamination. Replace the hose if damage is found.
3. Inspect the charge air cooler inlet air hose clamps (1). Replace the charge air cooler inlet air hose (2) if damage is found or the clamp components are missing.



2. Inspect the charge air cooler outlet air hose (2):
1. Use dish soap and water to clean the inside of the charge air cooler outlet air hose (2). Clean the interior of the hose, and allow to completely dry. Ensure any oil residue is removed from the hose internal interface surfaces.
2. Inspect the interior of the charge air cooler outlet air hose (2) for tears or delamination. Replace the hose if damage is found.
3. Inspect the charge air cooler outlet air hose clamps (1). Replace the charge air cooler outlet air hose (2) if damage is found or the clamp components are missing.

1. Clean the high pressure diesel fuel pump (1) mating surfaces.
2. Inspect the high pressure diesel fuel pump (1) for damage.
3. Replace fuel injection pump (1) if any damage is found.
4. Inspect the high pressure diesel fuel pump shaft notch (2) for damage.



5. Inspect the keyway (1) on the sprocket for damage.

1. Mark the NEW high pressure diesel fuel pump shaft in the same position as the marks on the old high pressure diesel fuel pump for ease of installation and ensuring it is timed correctly with the engine timing.



2. Lubricate the high pressure diesel fuel pump shaft (3). Adhesives, Fluids, Lubricants, and Sealers



3. Use the marks on the pump shaft and the sprocket to align and install the high pressure diesel fuel pump (1).



4. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
3. Apply thread locking adhesive to the external threads of the components.Adhesives, Fluids, Lubricants, and Sealers
4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

Caution: Refer to Fastener Caution.

5. Install the 3 fuel injection pump bolts (1) and tighten. Fastener Specifications
6. Connect the electrical connectors to the engine coolant temperature sensor and the block heater.
7. Position the hoses and harness as needed.



8. Connect the 2 high pressure diesel fuel pump electrical connectors (1).



9. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
3. Apply thread locking adhesive to the external threads of the components.Adhesives, Fluids, Lubricants, and Sealers
4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

Caution: Refer to Torque-to-Yield Fastener Caution.

10. Install a NEW fuel injection pump bolt (1) and tighten. Fastener Specifications
11. Remove the EN-52448-1 High Pressure Fuel Pump Tool.



12. Fuel Pump Access Hole Cover Seal(3)»Install NEW
13. Fuel Pump Access Hole Cover(2)»Install
14. Timing Chain Cover Bolt(1)»Install and tighten[2x]—Fastener Specifications
15. Transmission»Install—Automatic Transmission Removal and Installation



16. Install a NEW high pressure diesel fuel feed to rail pipe (2).
17. Hand tighten the 2 high pressure diesel fuel feed to rail pipe fittings (1) to the high pressure diesel fuel injection rail.



18. Install the 2 high pressure diesel fuel feed to rail pipe bracket bolts (1) and tighten. Fastener Specifications
19. Attach the fuel injector fuel return pipe retainer (2).



20. Install and tighten the 2 high pressure diesel fuel feed to rail pipe bracket bolts (1). Fastener Specifications



21. Hand tighten the 2 high pressure diesel fuel feed to rail pipe fittings (1) to the high pressure diesel fuel pump.
22. Tighten the high pressure diesel fuel feed to rail pipe fittings to both the high pressure diesel fuel pump and the high pressure diesel fuel injection rail. Fastener Specifications



23. Diesel Fuel Separator(1)»Install
24. Diesel Fuel Separator(1)»Connect—Metal Collar Quick Connect Fitting Service



25. Diesel Fuel Separator Bracket Bolt(1)»Install and tighten—Fastener Specifications



26. Fuel Injection Fuel Return Pipe (2)»Install
27. Fuel Injector Fuel Return Pipe Clamp (1)»Engage—Hose Clamp Replacement Guidelines - Spring Type



28. Fuel Return Pipe(1)@Diesel Fuel Separator»Connect—Metal Collar Quick Connect Fitting Service



29. Fuel Pump Fuel Feed Hose(1)»Install
30. Fuel Pump Fuel Feed Hose(1)»Connect[2x]—Metal Collar Quick Connect Fitting Service



31. Fuel Feed Pipe Clip Bolt(1)»Install and tighten—Fastener Specifications
32. Front Wheelhouse Liner-Left Side»Install—Front Wheelhouse Liner Replacement




Danger: The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise canceling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.

33. Camshaft Housing Cover Insulator(1)»Install



34. Exhaust Gas Recirculation Pipe Bracket(5)»Install
35. Exhaust Gas Recirculation Pipe Bracket Bolt(1)»Install and tighten—Fastener Specifications
36. Reposition harness, hoses, and connect electrical connectors as needed.



37. Charge Air Cooler Bracket(2)»Install
38. Charge Air Cooler Bracket Bolt(1)»Install and tighten[5x]—Fastener Specifications



39. Engine Coolant Air Bleed Hose Clip(1)»Install



40. Oil Filler Tube Support Stud(1)»Install and tighten—Fastener Specifications



41. Engine Wiring Harness Bracket(3)»Install
42. Engine Wiring Harness Bracket Nut(1)»Install and tighten[2x]—Fastener Specifications



43. Turbocharger Bracket Bolt(1)»Install and tighten—Fastener Specifications



44. Intake Manifold Resonator(2)»Install
45. Engage the retaining spring (1).



46. Turbocharger Heat Shield(1)»Install



47. Turbocharger Heat Shield Nut(2)»Install and tighten—Fastener Specifications
48. Turbocharger Heat Shield Bolt(1)»Install and tighten[2x]—Fastener Specifications



49. Install the upper intake manifold bracket (2) with the NOX sensor attached.
50. Upper Intake Manifold Brace Nut(1)»Install and tighten[3x]—Fastener Specifications



51. Charge Air Cooler(1)»Install



52. Charge Air Cooler Bolt(1)»Install and tighten[4x]—Fastener Specifications



53. Charge Air Cooler Inlet Air Hose(2)»Install
54. Charge Air Cooler Inlet Air Hose Clamp(1)»Tighten[2x]—Fastener Specifications



55. Charge Air Cooler Outlet Air Hose(2)»Install
56. Charge Air Cooler Outlet Air Hose Clamp (1)»Tighten[2x]—Fastener Specifications



57. Connect the nitrogen oxides sensor electrical connector.
58. Wiring Harness Retainer(4)@Charge Air Cooler»Install



59. Wiring Harness Retainer(2)@Charge Air Cooler»Install[3x]
60. Electrical Connector(1)@Charge Air Cooler»Connect[2x]



61. Install a NEW exhaust gas recirculation cooler inlet pipe gasket (3).
62. Install a NEW exhaust gas recirculation pipe seal (2).
63. Install the exhaust gas recirculation pipe (1).




Note: Note: Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.

64. Exhaust Gas Recirculation Outlet Pipe Bolt(1)»Install and hand tighten[2x]



65. Install and hand tighten the exhaust gas recirculation outlet pipe bolt (2).
66. Install the turbocharger coolant return hose clip (1).



67. Install and hand tighten the 2 exhaust gas recirculation pipe bolts (1).




Note: Note: Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.

68. Exhaust Gas Recirculation Outlet Pipe Bolt(1)»Tighten in sequence[2x]—Fastener Specifications



69. Exhaust Gas Recirculation Outlet Pipe Bolt(2)»Tighten in sequence[2x]—Fastener Specifications
70. Install the turbocharger coolant return hose clip (1).



71. Exhaust Gas Recirculation Outlet Pipe Bolt(1)»Tighten in sequence[2x]—Fastener Specifications



72. Turbocharger Coolant Feed and Return Pipe Bolt(3)»Install and tighten—Fastener Specifications



73. Engine Coolant Air Bleed Hose(2)»Reposition
74. Engine Coolant Outlet Pipe Bracket Bolt(1)»Install and tighten—Fastener Specifications



75. Install the rear engine wiring harness channel (2).
76. Engine Wiring Harness Bracket Nut(1)»Install and tighten[3x]—Fastener Specifications.



77. Air Cleaner Outlet Duct(2)»Install
78. Air Cleaner Outlet Duct Clamp(1)»Tighten—Fastener Specifications



79. Air Cleaner Outlet Front Duct(2)»Install
80. Air Cleaner Outlet Duct Clamp(1)»Tighten[2x]—Fastener Specifications



81. Oil Filler Cap»Remove
82. Intake Manifold Cover(2)»Install
83. Intake Manifold Cover Bolt(1)»Install and tighten—Fastener Specifications
84. Oil Filler Cap»Install
85. Plenum Front Panel Outer Reinforcement»Install—Plenum Front Panel Outer Reinforcement Removal and Installation
86. Prime the fuel system and inspect for leaks. Fuel System Priming
87. Perform the high pressure fuel variable reset. High Pressure Fuel Variable Reset