Contents: Removal procedure ↧ Installation procedure ↧
Removal procedure
Caution: Do not remove if exhaust manifold parts are hot.
1. Disconnect the negative battery cable.
2. Remove the decorative cover. See "Decorative cover" in this section.
3. Remove the air intake hoses and ducts. See "Air injection system" in this section.
4. Remove the positive crankcase ventilation (PCV) valve and adapter. See "Positive Crankcase Ventilation (PCV) Valve and Adapter" in this section.
5. Remove the exhaust heat shield.
6. Remove the pre-catalytic converter. See Section 1G1, Exhaust System - 2.0 Diesel.
7. Remove the turbocharger from the exhaust manifold. See Section 1F1, Engine Controls - 2.0 Diesel.
8. Remove the intake pipe of the exhaust gas recirculation cooler from the exhaust gas recirculation valve together with the gasket.
9. Remove the exhaust manifold together with the EGR cooler inlet pipe.
10. Remove the EGR cooler inlet pipe from the exhaust manifold.
Installation procedure
1. Install the EGR cooler inlet pipe to the exhaust manifold.
2. Install the exhaust manifold onto the cylinder head with a new gasket.
3. Install the intake pipe of the exhaust gas recirculation cooler on the exhaust gas recirculation valve with a new gasket.
Tighten
Tighten the EGR cooler inlet pipe mounting nuts (to the exhaust manifold) up to 33 Nm (24.3 ft·lbs).
Tighten the exhaust manifold nuts to 33 Nm (24.3 ft·lbs).
Tighten the EGR cooler inlet pipe mounting bolts (to the EGR valve) up to 20 Nm (14.8 ft·lbs).
4. Install the exhaust manifold heat shield.
Tighten
Tighten the exhaust manifold heat shield bolt and nuts to 20 Nm (14.8 ft·lbs).
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