Removal Procedure

WARNING: This page is about a different variant/trim than selected.

Remove the engine sight shield. Engine Sight Shield Replacement
Drain the cooling system. Cooling System Draining and Filling
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Quick Connector Clamp (3) - Loosen
Charge Air Cooler Outlet Air Hose (1) @ Throttle Body (2) - Remove
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Engine Coolant Air Bleed Hose Connector (1) - Disconnect
Engine Coolant Air Bleed Hose (2) @ Retainer Clip (3) - Remove
Engine Coolant Air Bleed Hose (2) - Position aside
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Exhaust Gas Recirculation Cooler Temperature Sensor Electrical Connector (1) - Disconnect
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Exhaust Gas Recirculation Pipe Bolt (1, 4) - Remove [4x]
Exhaust Gas Recirculation Pipe (5) - Remove
Exhaust Gas Recirculation Cooler Pipe Gasket (2) - Remove and DISCARD
Exhaust Gas Recirculation Cooler Outlet Pipe Gasket (3) - Remove and DISCARD
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Remove the radiator surge tank outlet hose bracket bolt (2).
Exhaust Temperature Sensor Electrical Connector (3) - Disconnect
Radiator Surge Tank Overflow Hose Clamp (5) - Remove
Radiator Surge Tank Overflow Hose (4) @ Thermostat Bypass Pipe (6) - Disconnect
Hang the radiator surge tank engine hose bracket (1) along with the radiator surge tank overflow hose (5) aside.
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Exhaust Pressure Sensor Pipe Bolt (1) - Remove
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Disconnect the electrical connector:
1. Exhaust Gas Recirculation Valve (6)
2. Exhaust Gas Recirculation Vacuum Regulator Solenoid Valve (5)
3. Exhaust Pressure Differential Sensor (4)
4. Throttle Body (1)
Engine Wiring Harness Clip (3) - Unclip
Engine Wiring Harness (2) - Position aside
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Intake Manifold Brace Bolt (2) - Remove [5x]
Intake Manifold Brace (1) - Position aside
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Charge Air Bypass Regulator Solenoid Valve Inlet Tube (2) @ Exhaust Gas Recirculation Vacuum Regulator Solenoid Valve (1) - Disconnect
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Exhaust Pressure Differential Sensor Bolt (2) - Remove
Exhaust Pressure Differential Sensor (1) - Position aside
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Remove the turbocharger actuator pipe bracket bolt (1).
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Remove the 2 exhaust manifold pipe bolts (3).
Remove the exhaust manifold pipe (1) from the EGR cooler housing.
Remove and DISCARD the gasket. (2)
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Thermostat Bypass Hose Clamp (1) - Loosen
Thermostat Bypass Hose (3) @ Exhaust Gas Recirculation Cooler Housing (2) - Remove
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Quick Connector Clamp (1) - Loosen
Heater Outlet Hose (2) - Remove
Remove the turbocharger wastegate actuator vacuum control solenoid valve bracket bolt (3).
Turbocharger Wastegate Actuator Vacuum Control Solenoid Valve Bracket (4) - Position aside
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Remove the 3 EGR cooler housing bolts (2, 4).
Exhaust Gas Recirculation Cooler Housing (1) - Remove
Remove and DISCARD the gasket. (3)