Contents: Removal ↳ Installation ↳
Removal
All cars
1. Disconnect the ground cable from the battery. For additional information, refer to Section 414-01.
2. Remove the air cleaner. Refer to Section 303-12 for additional information.
3. Disconnect the positive crankcase ventilation (PCV) hose from the valve cover.
4. Remove the air cleaner outlet pipe.
- 1. Slide the clamp to release the pipe.
- 2. Remove the pipeline.
5. Disconnect the charge air cooler inlet pipe.
- 1. Release the clamp.
- 2. Unscrew the nut.
6. Remove the charge air cooler inlet pipe.
7. Disconnect the exhaust gas recirculation (EGR) line. Remove the two bolts.
Cars with EGR cooler
8.
NOTE: Mark the orientation of the EGR cooler clamp to ensure it is installed in the exact same position. When viewed from above, the clamp loop should be covered by the EGR cooler. This should allow access to the catalytic converter nuts.
Remove the EGR cooler clamp and discard it as no longer needed.
Vehicles without EGR cooler
9.
NOTE: Mark the orientation of the EGR cooler clamp to ensure it is installed in the exact same position. The loop of the clamp should be covered by the EGR line when viewed from the top of the engine. This should allow access to the catalytic converter nuts.
Remove the EGR pipe clamp and discard it as no longer needed.
All cars
10. Remove the EGR pipe.
Cars manufactured up to 06.1999.
11. Disconnect the oil feed line from the turbocharger. Discard the sealing washers as they are no longer needed.
Secure the lower control arm (right side shown).
12. Remove the catalytic converter. Refer to Section 309-00 for additional information.
13. Remove the engine roll limiter bolt. Move the engine as far forward as possible.
Cars with EGR cooler
14. Disconnect the EGR cooler and secure it to the side.
Cars manufactured up to 06.1999.
15. Disconnect the oil return line. Discard the O-ring as it is no longer needed.
Cars manufactured since 06.1999.
16. Disconnect the feed and return oil lines. Discard the gasket as it is no longer needed.
All cars
17. Lower the vehicle.
18. Remove the upper exhaust manifold mounting bolts.
19. Raise and support the vehicle. Refer to Section 100-02 for additional information.
20. Remove the catalytic converter support bracket from the cylinder block.
21. Disconnect the turbocharger assembly from the exhaust manifold. Discard the gasket as it is no longer needed.
22. Remove the turbocharger assembly with the exhaust manifold.
- 1. Move the engine as far forward as possible.
- 2. Remove the turbocharger.
Installation
All cars
1.
NOTE: Install a new exhaust manifold gasket.
NOTE: Install a new oil return line O-ring.
NOTE: Install new oil feed line sealing washers.
Install the lower exhaust manifold mounting bolts.
2. Install the catalytic converter support bracket.
3. Lower the vehicle.
4. Install the upper exhaust manifold mounting nuts and bolts.
Cars manufactured up to 06.1999.
5.
NOTE: Install new sealing washers.
Connect the oil supply line.
All cars
6. Raise and support the vehicle. Refer to Section 100-02 for additional information.
7. Connect the return oil line to the cylinder block.
Cars manufactured since 06.1999.
8.
NOTE: Make sure the feed and return oil lines are installed correctly.
Install new supply and return oil lines.
9. Install the feed and return oil lines.
Cars manufactured up to 06.1999.
10.
Note: Install a new O-ring.
Install the return oil line.
Cars with EGR cooler
11.
NOTE: Do not tighten the bolts at this stage.
Install the EGR cooler mounting bolts (finger tighten and then loosen 1.5 turns).
All cars
12. Lower the vehicle.
13.
NOTE: Do not tighten the bolts at this stage.
Install the EGR pipe (hand tighten the EGR pipe to EGR valve mounting bolts).
Vehicles without EGR cooler
14.
CAUTION: To ensure uniform compression of the EGR pipe gasket when installing the pipe clamp, pipe movement must not be restricted by the pipe bolts.
NOTE: Ensure that the clamp is installed in the same position as it was before removal.
Install a new EGR line clamp.
Cars with EGR cooler
15.
CAUTION: To ensure uniform compression of the EGR cooler gasket when installing the cooler clamp, cooler movement must not be restricted by the cooler bolts.
NOTE: Make sure the EGR cooler clamp is installed in the same position from which it was removed.
Install the new EGR cooler clamp.
16. Raise and support the vehicle. Refer to Section 100-02 for additional information.
17. Tighten the EGR cooler mounting bolts to the cylinder block.
All cars
18. Install the engine roll limiter bolt.
19. Install the catalytic converter. Refer to Section 309-00 for additional information.
20. Tighten the EGR pipe mounting bolts to the EGR valve.
21. Connect the charge air cooler inlet pipe.
22.
CAUTION: Make sure that the inside of the charge air cooler intake pipe is clean and free of oil, as this will reduce the adhesion when connecting the pipe to the charge air cooler. Failure to follow this instruction may result in engine damage.
Install the charge air cooler inlet pipe.
- 1. Tighten the clamp.
- 2. Tighten the nut.
23. Install the air cleaner outlet pipe.
- 1. Install the pipeline.
- 2. Slide the clamp to position the pipe in the desired position.
24. Connect the PCV hose to the valve cover.
25. Install the air cleaner. Refer to Section 303-12 for additional information.
26. Connect the ground cable to the battery. For additional information, refer to Section 414-01.