Removal Procedure
In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.
Avoid contact with HOT components. Wear safety glasses and protective gloves to avoid personal injury.
- Disconnect the battery. Battery Negative Cable Disconnection and Connection
- Remove the oil fill cap.
Intake Manifold Cover Bolt (1) - Remove [2x]
- Lift up on the front of the intake manifold cover (2).
Intake Manifold Cover (1) @ Upper Intake Manifold Bracket (2) - Remove
Air Cleaner Outlet Duct Clamp (1) - Loosen [2x]
- Evaporative Emission Canister Purge Tube (2) - Disconnect - Plastic Collar Quick Connect Fitting Service
- Positive Crankcase Ventilation Tube (3) - Disconnect - Plastic Collar Quick Connect Fitting Service
- Electrical Connector @ Evaporative Emission Canister Purge Solenoid Valve - Disconnect
Air Cleaner Outlet Duct (1) - Remove
- Disconnect the electrical connector and remove all wiring harnesses from the air cleaner assembly.
Air Cleaner Bolt (1) - Remove
Air Cleaner Assembly (1) - Remove
- CAUTION:
Refer to Heated Oxygen and Oxygen Sensor Caution .
CAUTION:The use of excessive force may damage the threads in the exhaust manifold/pipe.
NOTE:The heated oxygen sensor MAY be difficult to remove when the engine temperature is less than 48°C (120°F).
NOTE:The heated oxygen sensor in-line connector and louvered end MUST be kept clear of all grease, dirt, and other contaminants. Do NOT use cleaning solvents of any type. Do NOT drop or roughly handle the sensor.
Disconnect and reposition electrical connectors as necessary.
- Using the EN-6179 Heated Oxygen Sensor Remover/Installer, remove the heated oxygen sensor (1).
Turbocharger Heat Shield Bolt (1) - Remove [2x]
Turbocharger Heat Shield Bolt (1) - Remove [2x]
Turbocharger Heat Shield (1) - Remove
Retainer Spring (1) - Release
- Charge Air Cooler Inlet Air Tube (2) @ Turbocharger (3) - Remove
Retainer (1) - Unclip
Water Pump Cover Bolt (1) - Remove [3x]
- Water Pump Cover (2) - Remove
- Install the engine support fixture. Engine Support Fixture
Engine Mount Nut (1) - Remove
- Use the EN-51007 Global Engine Support Fixture to raise the engine off the engine mount.
Engine Mount Bracket Bolt (1) - Remove and DISCARD [4x]
Engine Mount Bracket (1) - Remove
- Ensure the phenolic spacer remains in place.
- Raise and support the vehicle. Lifting and Jacking the Vehicle
- Disconnect and reposition electrical connectors as necessary.
- Using the appropriate tool, remove the heated oxygen sensor (1).
Floor Panel Number 4 Cross Bar Reinforcement Bolt (1) - Remove [6x]
- Floor Panel Reinforcement (2) - Remove
Catalytic Converter Nut (1) - Remove [2x]
Electrical Connector (1) @ Exhaust Control Valve Actuator - Disconnect [2x]
Exhaust Muffler (1) @ Exhaust Intermediate Pipe Insulator-Left Side (2) - Separate
- Exhaust Muffler (1) @ Exhaust Rear Muffler Insulator-Left Side (3) - Separate
Exhaust Muffler (1) @ Exhaust Intermediate Pipe Insulator-Right Side (2) - Separate
- Exhaust Muffler (1) @ Exhaust Rear Muffler Insulator-Right Side (3) - Separate
Exhaust Muffler (1) - Remove
- Catalytic Converter Gasket (2) - Remove and DISCARD
Front Crossmember Brace Nut (1) - Remove [4x]
- Front Crossmember Brace (2) - Remove
Exhaust Pipe Clamp (1) - Loosen
Catalytic Converter Brace Bracket Nut (1) - Remove [2x]
- Catalytic Converter Brace Bolt (2) - Remove [2x]
- Catalytic Converter Brace (3) - Remove
Warm Up Three-Way Catalytic Converter (1) - Remove
- Exhaust Pipe Clamp (2) - Remove and DISCARD
- Catalytic Converter Gasket (3) - Remove and DISCARD
Compressor Air Intake Turbocharger Wastegate Actuator Link Spring (1) - Remove
- Compressor Air Intake Turbocharger Wastegate Actuator Link Clip (2) - Remove
- Compressor Air Intake Turbocharger Wastegate Actuator Rod (3) @ Turbocharger Wastegate Actuator - Disconnect
Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Turbocharger Coolant Feed and Return Pipe (2) @ Exhaust Manifold Outlet Pipe - Remove
Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Turbocharger Coolant Feed Hose (2) @ Turbocharger Coolant Feed and Return Pipe - Remove
Turbocharger Coolant Feed and Return Pipe Bolt (1) - Remove [2x]
Turbocharger Coolant Feed and Return Pipe (1) - Remove
- Turbocharger Coolant Feed and Return Pipe Gasket (2) - Remove and DISCARD
Retainer (1) - Disconnect [3x]
- Electrical Connector (2) - Disconnect [2x]
- Reposition the front axle vent hose (3), and electrical harness (4).
- CAUTION:
The Positive Crankcase Ventilation (PCV) line is tamper resistant and must always be replaced once it is removed. The fittings connected to the PCV line must also be replaced if they are damaged when the PCV line is removed. To reduce the risk of damage to the fittings, use a suitable cutting tool and carefully cut the connections away.
NOTE:Disconnecting the tamper resistant connections will damage the positive crankcase ventilation tube, it must be replaced after removal.
Use a suitable tool to disconnect the 6 locking tabs at each temper resistant connection.
- Positive Crankcase Ventilation Tube (1) - Remove and DISCARD
Turbocharger Brace Nut (1) - Remove
- Turbocharger Bracket Bolt (2) - Remove [2x]
- Turbocharger Brace (3) - Remove
- Turbocharger Oil Feed Pipe Bolt (4) - Remove [4x]
Turbocharger Nut (1) - Remove and DISCARD [2x]
- Turbocharger Bolt (2) - Remove and DISCARD [2x]
Turbocharger Assembly (1) - Remove
- Turbocharger Gasket (2) - Remove and DISCARD
Turbocharger Oil Feed Pipe Bolt (1) @ Compressor Air Intake Turbocharger - Remove [2x]
- Turbocharger Oil Feed Pipe (2) - Remove
- Turbocharger Oil Return Pipe Gasket (3) - Remove and DISCARD
- Turbocharger Oil Feed Pipe Gasket (4) - Remove and DISCARD
- Turbocharger Oil Return Pipe Gasket (5) - Remove and DISCARD
Turbocharger Stud (1) - Remove and DISCARD [2x]
Phenolic spacer must be present to prevent galvanic/corrosive reaction and/or excessive temperature conduction between engine mount bracket and engine mount. Replace mount if phenolic spacer is missing or damaged. Failure to ensure phenolic spacer is intact and not damaged can lead to premature failure of engine mount and/or engine mount bracket.
The heated oxygen sensor MAY be difficult to remove when the engine temperature is less than 48°C (120°F).
The heated oxygen sensor in-line connector and louvered end MUST be kept clear of all grease, dirt, and other contaminants. Do NOT use cleaning solvents of any type. Do NOT drop or roughly handle the sensor.
When removing, handling or installing this component wear protective gloves. The sharp edges on the component may be very sharp and may cause injury.