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.
Air Cleaner Bolt (1) - Remove
- 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 (4) - Disconnect [2x]
Air Cleaner Outlet Duct Clamp (1) - Loosen
- Wiring Harness Retainer (2) @ Air Cleaner Assembly - Remove [4x]
- Engine Wiring Harness (3) - Reposition
Remove the air cleaner (1) and air cleaner outlet duct (2) as an assembly.
- Disconnect and reposition electrical connectors as necessary.
- 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 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.
NOTE:The heated oxygen sensor MAY be difficult to remove when the engine temperature is less than 48°C (120°F).
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
- Raise and support the vehicle. Lifting and Jacking the Vehicle
- Disconnect and reposition electrical connectors as necessary.
- Using the EN-6179 Heated Oxygen Sensor Remover/Installer, 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
{ If equipped } Front Crossmember Brace Nut (1) - Remove [4x]
- { If equipped } Front Crossmember Brace (2) - Remove
Exhaust Muffler (1) - Remove
- Catalytic Converter Gasket (2) - Remove and DISCARD
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
Front Axle Propeller Shaft Heat Shield Bolt (1) - Remove [2x]
- Front Axle Propeller Shaft Heat Shield Stud (2) - Remove
- Front Axle Propeller Shaft Heat Shield (3) - Remove
- Support the transmission with an appropriate jack.
Transmission Mount Bracket Bolt (1) - Remove [4x]
- NOTE:
The transmission mount bolt is retained in the mount, loosen the bolt to disengage the threads and remove the mount and bolt as an assembly.
Transmission Mount Bolt (1) - Remove
- Transmission Mount (2) - Remove
Transfer Case Front Output Shaft Boot Clamp (1) @ Transfer Case Front Output Shaft - Remove and DISCARD
- Release the transfer case front output shaft boot (2) from the groove in the transfer case front output shaft.
Mark the relationship between the front axle propeller shaft (2) and the front differential carrier flange with a grease pencil.
- Front Axle Propeller Shaft Bolt (1) - Remove [6x]
- Front Axle Propeller Shaft Washer (3) - Remove [3x]
Front Axle Propeller Shaft (1) - Remove
Inspect the transfer case front output shaft boot (1), if damage is found, remove and DISCARD the transfer case front output shaft boot clamp (2) and the transfer case front output shaft boot (1).
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.