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Tahoe / Yukon Service Manual

Exhaust Manifold Replacement

Single Use Fasteners and Components Air Conditioning Compressor and Condenser Hose Seal - Large Air Conditioning Compressor and Condenser Hose Seal - Small Air Conditioning Evaporator Thermal Expansion Valve Seal - Large Air Conditioning Evaporator Thermal Expansion Valve Seal - Small Catalytic Converter Clamp Catalytic Converter Gasket Emission Reduction Fluid Injector Clamp Exhaust Gas Recirculation Cooler Inlet Pipe Gasket [2x] Exhaust Gas Recirculation Outlet Pipe Gasket Exhaust Gas Recirculation Pipe Seal Exhaust Gas Recirculation Valve Cooler Gasket Exhaust Gas Recirculation Valve Inlet Gasket [2x] Exhaust Manifold Gasket Exhaust System Front Gasket [2x] Turbocharger Coolant Feed and Return Pipe Gasket Turbocharger Gasket Turbocharger Nut [3x] Turbocharger Oil Feed Pipe Gasket Turbocharger Oil Return Pipe Gasket

  1. Recover the refrigerant. Refrigerant Recovery and Recharging
Exhaust Manifold Replacement — figure 1
Exhaust Manifold Replacement — figure 1
  1. Plenum Front Panel Outer Reinforcement (1) » Remove — Plenum Front Panel Outer Reinforcement Removal and Installation
  2. Oil Filler Cap » Remove
Exhaust Manifold Replacement — figure 2
Exhaust Manifold Replacement — figure 2
  1. Intake Manifold Cover Bolt (1) » Remove
  2. Intake Manifold Cover (2) » Remove
  3. Install the oil filler cap after removal of the intake manifold cover to prevent debris from falling into the engine.
Exhaust Manifold Replacement — figure 3
Exhaust Manifold Replacement — figure 3
  1. Battery Hold Down Strap Bolt (1) » Remove [2x]
  2. Battery Hold Down Strap (2) » Remove
Exhaust Manifold Replacement — figure 4
Exhaust Manifold Replacement — figure 4
  1. Retaining Tab (1) » Disengage [2x]
  2. Front Compartment Fuse Block Cover (2) » Remove
Exhaust Manifold Replacement — figure 5
Exhaust Manifold Replacement — figure 5
  1. Battery Positive Post Clamp Nut (1) » Loosen
Exhaust Manifold Replacement — figure 6
Exhaust Manifold Replacement — figure 6
  1. Electrical Connector (1) » Disconnect
Exhaust Manifold Replacement — figure 7
Exhaust Manifold Replacement — figure 7
  1. Retaining Tab (1) » Disengage [3x]
  2. Battery Distribution Engine Compartment Fuse Block (2) » Reposition
Exhaust Manifold Replacement — figure 8
Exhaust Manifold Replacement — figure 8
  1. Battery Hold Down Retainer Bolt (1) » Remove
  2. Battery Hold Down Retainer (2) » Remove
Exhaust Manifold Replacement — figure 9
Exhaust Manifold Replacement — figure 9
  1. Battery (1) » Remove
Exhaust Manifold Replacement — figure 10
Exhaust Manifold Replacement — figure 10
  1. Retaining Tab (1) » Disengage [2x]
  2. Engine Wiring Harness Junction Block Cover (2) » Remove
  3. Battery Positive Cable Nut (3) » Remove
  4. Starter Solenoid Cable (4) » Remove
Exhaust Manifold Replacement — figure 11
Exhaust Manifold Replacement — figure 11
  1. Engine Wiring Harness Junction Block Bolt (2) » Loosen [4x]
  2. Retaining Tab (1) » Disengage [4x]
  3. Engine Wiring Harness Junction Block (3) » Remove
Exhaust Manifold Replacement — figure 12
Exhaust Manifold Replacement — figure 12
  1. Electrical Connector (1) » Remove [4x]
Exhaust Manifold Replacement — figure 13
Exhaust Manifold Replacement — figure 13
  1. Engine Wiring Harness Fuse Block Bracket Bolt (2) » Remove [2x]
  2. Retaining Tab (1) » Disengage
  3. Engine Wiring Harness Fuse Block Bracket (3) » Remove
Exhaust Manifold Replacement — figure 14
Exhaust Manifold Replacement — figure 14
  1. Air Conditioning Compressor and Condenser Hose Nut (2) @ Air Conditioning Refrigerant Heat Exchanger » Remove
  2. Air Conditioning Compressor and Condenser Hose (3) @ Air Conditioning Refrigerant Heat Exchanger » Remove
  3. Air Conditioning Compressor and Condenser Hose Seal - Large (4) » Remove and DISCARD
  4. Air Conditioning Condenser and Evaporator Hose Clip (6) » Remove
  5. Air Conditioning Condenser and Evaporator Hose (1) » Remove
  6. Air Conditioning Compressor and Condenser Hose Seal - Small (5) » Remove and DISCARD
Exhaust Manifold Replacement — figure 15
Exhaust Manifold Replacement — figure 15
  1. Air Conditioning Refrigerant Heat Exchanger Nut (1) @ Battery Tray » Remove
Exhaust Manifold Replacement — figure 16
Exhaust Manifold Replacement — figure 16
  1. Air Conditioning Evaporator Thermal Expansion Valve Hose Nut (1) » Remove
  2. Air Conditioning Refrigerant Heat Exchanger (2) » Remove
  3. Air Conditioning Evaporator Thermal Expansion Valve Seal - Large (3) » Remove and DISCARD
  4. Air Conditioning Evaporator Thermal Expansion Valve Seal - Small (4) » Remove and DISCARD
  5. Remove retainers as needed.
Exhaust Manifold Replacement — figure 17
Exhaust Manifold Replacement — figure 17
  1. Battery Tray Bolt (1) » Remove [7x]
Exhaust Manifold Replacement — figure 18
Exhaust Manifold Replacement — figure 18
  1. Battery Tray (1) » Remove
Exhaust Manifold Replacement — figure 19
Exhaust Manifold Replacement — figure 19
  1. Exhaust Gas Recirculation Cooler Temperature Sensor (2) » Remove and position aside
Exhaust Manifold Replacement — figure 20
Exhaust Manifold Replacement — figure 20
  1. Turbocharger Heat Shield Bolt (1) » Remove [2x]
  2. Turbocharger Heat Shield Nut (2) » Remove
Exhaust Manifold Replacement — figure 21
Exhaust Manifold Replacement — figure 21
  1. Turbocharger Heat Shield (1) » Remove
Exhaust Manifold Replacement — figure 22
Exhaust Manifold Replacement — figure 22
  1. Catalytic Converter Clamp (1) » Loosen
Exhaust Manifold Replacement — figure 23
Exhaust Manifold Replacement — figure 23
  1. Nitrogen Oxides Sensor (2) » Remove
Exhaust Manifold Replacement — figure 24
Exhaust Manifold Replacement — figure 24
  1. Exhaust Temperature Sensor - Position 1 (1) » Remove and position aside
Exhaust Manifold Replacement — figure 25
Exhaust Manifold Replacement — figure 25
  1. Exhaust Temperature Sensor - Position 2 (1) » Remove and position aside
Exhaust Manifold Replacement — figure 26
Exhaust Manifold Replacement — figure 26
  1. Emission Reduction Fluid Exhaust Front Pipe Injector Supply Pipe Insulator (1) » Remove
Exhaust Manifold Replacement — figure 27
Exhaust Manifold Replacement — figure 27
  1. Emission Reduction Fluid Injector Clamp (1) » Remove and DISCARD
  1. Reductant Fluid Injector (2) » Reposition
  1. Exhaust System Front Gasket (3) » Remove and DISCARD
  2. Clean the exhaust mounting flange and injector mounting surfaces to remove any soot or emission reduction fluid deposits.
  3. Front Wheelhouse Liner - Right Side (3) » Remove — Front Wheelhouse Liner Replacement
  4. Drain the cooling system. Cooling System Draining and Filling
Exhaust Manifold Replacement — figure 28
Exhaust Manifold Replacement — figure 28
  1. Exhaust Temperature Sensor - Position 3 (1) » Remove and position aside
Exhaust Manifold Replacement — figure 29
Exhaust Manifold Replacement — figure 29
  1. Using a suitable tool, remove the position 2 nitrogen oxides sensor (1) from the nitrogen oxides catalytic converter.
Exhaust Manifold Replacement — figure 30
Exhaust Manifold Replacement — figure 30
  1. Using a suitable tool, remove the position 3 nitrogen oxides sensor (1) from the nitrogen oxides catalytic converter.
Exhaust Manifold Replacement — figure 31
Exhaust Manifold Replacement — figure 31
  1. Using a suitable tool, remove the exhaust particulate sensor (1) from the nitrogen oxides catalytic converter.
Exhaust Manifold Replacement — figure 32
Exhaust Manifold Replacement — figure 32
  1. Exhaust Pipe Clamp (1) » Loosen
Exhaust Manifold Replacement — figure 33
Exhaust Manifold Replacement — figure 33
  1. Exhaust Front Pipe Nut (1) » Remove [2x]
Exhaust Manifold Replacement — figure 34
Exhaust Manifold Replacement — figure 34
  1. Catalytic Converter Brace Bracket Nut (1) » Remove [2x]
  2. Wiring Harness Retainer (2) @ Catalytic Converter Brace Bracket (3) » Remove
  3. Catalytic Converter Brace Bracket (3) » Remove
Exhaust Manifold Replacement — figure 35
Exhaust Manifold Replacement — figure 35
  1. Exhaust Front Pipe Nut (1) » Remove [2x]
Exhaust Manifold Replacement — figure 36
Exhaust Manifold Replacement — figure 36
  1. Nitrogen Oxides Catalytic Converter (1) » Remove
  2. Exhaust System Front Gasket (2) » Remove and DISCARD
Exhaust Manifold Replacement — figure 37
Exhaust Manifold Replacement — figure 37
  1. Electrical Connector (1) @ Exhaust Back Pressure Valve » Disconnect
Exhaust Manifold Replacement — figure 38
Exhaust Manifold Replacement — figure 38
  1. Exhaust Gas Recirculation Valve Cooling Return Pipe Bolt (1) » Remove [2x]
  2. Exhaust Gas Recirculation Valve Cooling Return Pipe (2) » Remove
  3. Turbocharger Coolant Feed and Return Pipe Gasket (3) » Remove and DISCARD
Exhaust Manifold Replacement — figure 39
Exhaust Manifold Replacement — figure 39
  1. Catalytic Converter Nut (1) » Remove [3x]
Exhaust Manifold Replacement — figure 40
Exhaust Manifold Replacement — figure 40
  1. Exhaust Back Pressure Valve (1) » Remove
  2. Exhaust Gas Recirculation Valve Inlet Gasket (2) » Remove and DISCARD
Exhaust Manifold Replacement — figure 41
Exhaust Manifold Replacement — figure 41
  1. Air Cleaner Outlet Duct Clamp (1) » Loosen [2x]
  2. Air Cleaner Outlet Front Duct (2) » Remove
Exhaust Manifold Replacement — figure 42
Exhaust Manifold Replacement — figure 42
  1. Air Cleaner Outlet Duct Clamp (1) » Loosen
  2. Air Cleaner Outlet Duct (2) » Remove
Exhaust Manifold Replacement — figure 43
Exhaust Manifold Replacement — figure 43
  1. Hose Clamp (1) » Disengage [4x] — Hose Clamp Replacement Guidelines - Spring Type
  2. Exhaust Gas Recirculation Coolant Return Pipe (2) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Remove
  3. Heater Inlet Hose (3) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Remove
  4. Exhaust Gas Recirculation Cooler Outlet Pipe (4) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Remove
  5. Exhaust Gas Recirculation Cooler Inlet Pipe (5) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Remove
Exhaust Manifold Replacement — figure 44
Exhaust Manifold Replacement — figure 44
  1. Hose Clamp (1) » Disengage — Hose Clamp Replacement Guidelines - Spring Type
  2. Thermostat Bypass Hose (2) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Remove
Exhaust Manifold Replacement — figure 45
Exhaust Manifold Replacement — figure 45
  1. Hose Clamp (1) » Disengage [2x] — Hose Clamp Replacement Guidelines - Spring Type
  2. Exhaust Gas Recirculation Valve Cooling Return Hose (3) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Remove
  3. Turbocharger Coolant Feed and Return Pipe (4) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Remove
Exhaust Manifold Replacement — figure 46
Exhaust Manifold Replacement — figure 46
  1. Exhaust Gas Recirculation Pipe Bracket Bolt (1) » Remove [2x]
Exhaust Manifold Replacement — figure 47
Exhaust Manifold Replacement — figure 47
  1. Exhaust Gas Recirculation Cooler Inlet Pipe (1) » Remove
Exhaust Manifold Replacement — figure 48
Exhaust Manifold Replacement — figure 48
  1. Remove the 3 rear engine wiring harness channel nuts (1).
  2. Position the rear engine wiring harness channel (2) out of the way.
Exhaust Manifold Replacement — figure 49
Exhaust Manifold Replacement — figure 49
  1. Remove the 2 exhaust pressure differential sensor bracket studs (1) and reposition the exhaust pressure differential bracket (2).
Exhaust Manifold Replacement — figure 50
Exhaust Manifold Replacement — figure 50
  1. Disengage the exhaust pressure differential sensor hose clamp (1) and remove the exhaust pressure differential sensor from the exhaust gas recirculation valve hose. Hose Clamp Replacement Guidelines - Spring Type
Exhaust Manifold Replacement — figure 51
Exhaust Manifold Replacement — figure 51
  1. Disengage the exhaust pressure differential sensor hose clamp (1) and remove the exhaust pressure differential sensor at the exhaust gas recirculation cooler. Hose Clamp Replacement Guidelines - Spring Type
Exhaust Manifold Replacement — figure 52
Exhaust Manifold Replacement — figure 52
  1. Disengage the 2 exhaust pressure differential sensor hose clamp (1) and remove the 2 exhaust pressure differential sensor hoses at the exhaust gas recirculation cooler. Hose Clamp Replacement Guidelines - Spring Type
Exhaust Manifold Replacement — figure 53
Exhaust Manifold Replacement — figure 53
  1. Exhaust Gas Recirculation Pipe Nut (1) » Remove
Exhaust Manifold Replacement — figure 54
Exhaust Manifold Replacement — figure 54
  1. Exhaust Gas Recirculation Pipe Nut (1) » Remove
Exhaust Manifold Replacement — figure 55
Exhaust Manifold Replacement — figure 55
  1. Exhaust Gas Recirculation Pipe (1) » Reposition
  2. Exhaust Gas Recirculation Outlet Pipe Gasket (2) » Remove and DISCARD
Exhaust Manifold Replacement — figure 56
Exhaust Manifold Replacement — figure 56
  1. Exhaust Gas Recirculation Valve Bracket Nut (1) » Remove
  2. Heater Inlet Hose Bracket (2) » Reposition
Exhaust Manifold Replacement — figure 57
Exhaust Manifold Replacement — figure 57
  1. Disconnect the electrical connector (1).
  2. Exhaust Gas Recirculation Pipe Bolt (2) » Remove [2x]
Exhaust Manifold Replacement — figure 58
Exhaust Manifold Replacement — figure 58
  1. Exhaust Gas Recirculation Pipe Bolt (1) » Remove [2x]
Exhaust Manifold Replacement — figure 59
Exhaust Manifold Replacement — figure 59
  1. Remove the exhaust gas recirculation valve (1) with the exhaust gas recirculation valve hose.
  2. Exhaust Gas Recirculation Valve Cooler Gasket (2) » Remove and DISCARD
Exhaust Manifold Replacement — figure 60
Exhaust Manifold Replacement — figure 60
  1. Exhaust Gas Recirculation Cooler Inlet Pipe Bolt (1) » Remove [4x]
  2. Exhaust Gas Recirculation Pipe (2) » Remove
  3. Exhaust Gas Recirculation Cooler Inlet Pipe Gasket (3) Remove and DISCARD [2x]
Exhaust Manifold Replacement — figure 61
Exhaust Manifold Replacement — figure 61
  1. Disconnect the electrical connector at exhaust gas recirculation cooler.
  2. Remove the 4 exhaust gas recirculation cooler nuts (1).
Exhaust Manifold Replacement — figure 62
Exhaust Manifold Replacement — figure 62
  1. Remove the exhaust gas recirculation cooler (1).
Exhaust Manifold Replacement — figure 63
Exhaust Manifold Replacement — figure 63
  1. Catalytic Converter Brace Bracket Nut (1) » Remove [2x]
Exhaust Manifold Replacement — figure 64
Exhaust Manifold Replacement — figure 64
  1. Catalytic Converter Brace Bracket Nut (1) » Loosen [2x]
Exhaust Manifold Replacement — figure 65
Exhaust Manifold Replacement — figure 65
  1. Fuel Heater Inlet and Outlet Nut (1) » Remove
  2. Fuel Cooler Coolant Cooler Inlet Hose » Reposition
Exhaust Manifold Replacement — figure 66
Exhaust Manifold Replacement — figure 66
  1. Catalytic Converter Brace Bracket Nut (1) » Loosen [2x]
  2. Reposition hoses and wiring harness as needed.
Exhaust Manifold Replacement — figure 67
Exhaust Manifold Replacement — figure 67
  1. Nitrogen Oxides Catalytic Converter (1) » Remove
  2. Catalytic Converter Clamp (2) » Remove and DISCARD
  3. Catalytic Converter Gasket (3) » Remove and DISCARD
Exhaust Manifold Replacement — figure 68
Exhaust Manifold Replacement — figure 68
  1. Positive Crankcase Ventilation Hose Clamp (1) » Disengage — Hose Clamp Replacement Guidelines - Spring Type
  2. Positive Crankcase Ventilation Hose (2) @ Turbocharger » Remove
Exhaust Manifold Replacement — figure 69
Exhaust Manifold Replacement — figure 69
  1. Turbocharger Bracket Bolt (1) » Remove
  2. Turbocharger Bracket Nut (2) » Remove [2x]
  3. Turbocharger Bracket Brace (3) » Remove
Exhaust Manifold Replacement — figure 70
Exhaust Manifold Replacement — figure 70
  1. Hose Clamp (1) » Disengage — Hose Clamp Replacement Guidelines - Spring Type
  2. Turbocharger Coolant Return Hose (2) @ Turbocharger Coolant Feed Pipe » Remove
  3. Turbocharger Coolant Feed Pipe Bolt (3) » Remove
Exhaust Manifold Replacement — figure 71
Exhaust Manifold Replacement — figure 71
  1. Release the retainer spring (1).
  2. Intake Manifold Resonator (2) » Remove
Exhaust Manifold Replacement — figure 72
Exhaust Manifold Replacement — figure 72
  1. Chassis Front Wiring Harness Bracket Bolt - Rear (1) » Remove
  2. Chassis Wiring Harness Front Bracket Retainer (2) » Remove [2x]
  3. Chassis Front Wiring Harness Bracket Bolt - Front (3) » Remove
  4. Remove the positive battery cable retainers from the chassis wiring harness front bracket.
  5. Chassis Wiring Harness (4) » Reposition
Exhaust Manifold Replacement — figure 73
Exhaust Manifold Replacement — figure 73
  1. Starter Heat Shield Bolt (1) » Remove
  2. Starter Heat Shield Bolt (2) » Remove [2x]
Exhaust Manifold Replacement — figure 74
Exhaust Manifold Replacement — figure 74
  1. Starter Heat Shield (1) » Remove
Exhaust Manifold Replacement — figure 75
Exhaust Manifold Replacement — figure 75
  1. Starter Solenoid Cable Nut (1) » Remove
  2. Wiring Harness Conduit Nut (2) » Remove
  3. Starter Solenoid Cable (3) » Remove
Exhaust Manifold Replacement — figure 76
Exhaust Manifold Replacement — figure 76
  1. Starter Bolt (1) » Remove [3x]
  2. Reposition the starter (2) to access the electrical connector.
Exhaust Manifold Replacement — figure 77
Exhaust Manifold Replacement — figure 77
  1. Reposition the protective sleeve (2).
  2. Electrical Connector (1) » Disconnect
Exhaust Manifold Replacement — figure 78
Exhaust Manifold Replacement — figure 78
  1. Remove the starter (1) through the wheel well.
Exhaust Manifold Replacement — figure 79
Exhaust Manifold Replacement — figure 79
  1. Turbocharger Oil Feed Pipe Bolt (1) » Remove [2x]
  2. Turbocharger Oil Feed Pipe (2) » Remove
  3. Turbocharger Oil Feed Pipe Gasket (3) » Remove and DISCARD
Exhaust Manifold Replacement — figure 80
Exhaust Manifold Replacement — figure 80
  1. Lower Crankcase Extension Bolt (1) Remove
  2. Turbocharger Oil Return Pipe Bolt (2) » Remove [4x]
Exhaust Manifold Replacement — figure 81
Exhaust Manifold Replacement — figure 81
  1. Turbocharger Oil Feed Pipe (3) » Remove
  2. Turbocharger Oil Return Pipe Gasket (1) » Remove and DISCARD
  3. Turbocharger Oil Return Pipe Gasket (2) » Remove and DISCARD
  4. Disconnect connectors and retainers as needed from the turbocharger.
Exhaust Manifold Replacement — figure 82
Exhaust Manifold Replacement — figure 82
  1. Turbocharger Nut (1) » Remove and DISCARD [3x]
Exhaust Manifold Replacement — figure 83
Exhaust Manifold Replacement — figure 83
  1. Compressor Air Intake Turbocharger (1) » Remove
  2. Turbocharger Gasket (2) » Remove and DISCARD
Exhaust Manifold Replacement — figure 84
Exhaust Manifold Replacement — figure 84
  1. Exhaust Gas Recirculation Valve Bolt (1) » Remove [2x]
  2. Remove the exhaust gas recirculation valve (2) with the exhaust gas recirculation cooler inlet pipe.
  3. Exhaust Gas Recirculation Valve Inlet Gasket (3) » Remove and DISCARD
Exhaust Manifold Replacement — figure 85
Exhaust Manifold Replacement — figure 85
  1. Exhaust Manifold Heat Shield Bolt (1) » Remove [2x]
  2. Exhaust Manifold Heat Shield (2) » Remove
Exhaust Manifold Replacement — figure 86
Exhaust Manifold Replacement — figure 86
  1. Exhaust Manifold Flange Bolt (1) » Remove [12x]
  2. Exhaust Manifold (2) » Remove
  3. Exhaust Manifold Gasket (3) » Remove and DISCARD Cleaning and Inspection Procedure - Conditional
Exhaust Manifold Replacement — figure 87
Exhaust Manifold Replacement — figure 87
  1. Clean all sealing surfaces.
  2. Clean all threads if necessary.
  3. Inspect the wastegate regulator mechanism (1) for functionality.
  4. Inspect the turbine blades for damage or foreign material.
  5. Inspect the turbine blade shaft for excessive radial and axial end play.
  6. Inspect the compressor air intake turbocharger for cracks or other damage.
  7. Inspect the compressor air intake turbocharger mating surface for flatness.
Exhaust Manifold Replacement — figure 88
Exhaust Manifold Replacement — figure 88
  1. Clean the exhaust gas recirculation valve (1).
  2. Inspect the exhaust gas recirculation valve (1).
  3. Replace the exhaust gas recirculation valve (1) if any damage is found.
Exhaust Manifold Replacement — figure 89
Exhaust Manifold Replacement — figure 89
  1. Clean the exhaust gas recirculation valve (1).
  2. Inspect the exhaust gas recirculation valve (1).
  3. Replace the exhaust gas recirculation valve (1) if any damage is found.
Exhaust Manifold Replacement — figure 90
Exhaust Manifold Replacement — figure 90
  1. Clean the exhaust manifold (1) in solvent.
  2. Dry the exhaust manifold (1) with compressed air.
  3. Inspect the exhaust manifold (1) for damage.
Exhaust Manifold Replacement — figure 91
Exhaust Manifold Replacement — figure 91

  1. Using a straight edge (2) and a feeler gauge, measure the exhaust manifold mounting face (3) for warpage. An exhaust manifold face with warpage in excess of 0.2 mm (0.008 in) may cause an exhaust leak and may effect diagnostics and system performance.

  2. An exhaust manifold (1) which does not fall within the specifications must be replaced. Installation Procedure

  3. Exhaust Manifold Gasket (3) » Install NEW

  4. Exhaust Manifold (2) » Install

  1. Exhaust Manifold Flange Bolt (1) » Install and tighten [12x] — Fastener Specifications

  2. Exhaust Manifold Heat Shield (2) » Install

  3. Exhaust Manifold Heat Shield Bolt (1) » Install and tighten [2x] — Fastener Specifications

  4. Exhaust Gas Recirculation Valve Inlet Gasket (3) » Install NEW

  5. Install the exhaust gas recirculation valve (2) with the exhaust gas recirculation cooler inlet pipe.

  6. Exhaust Gas Recirculation Valve Bolt (1) » Install and tighten [2x] — Fastener Specifications

  7. Turbocharger Gasket (2) » Install NEW

  8. Turbocharger (1) » Install

  9. Turbocharger Nut (1) » Install NEW and tighten [3x] — Fastener Specifications

  10. Connect connectors and retainers as needed to the turbocharger.

  11. Turbocharger Oil Return Pipe Gasket (1) » Install NEW

  12. Turbocharger Oil Return Pipe Gasket (2) » Install NEW

  13. Turbocharger Oil Feed Pipe (3) » Install

  14. Turbocharger Oil Return Pipe Bolt (2) » Install and tighten [4x] — Fastener Specifications

  15. Lower Crankcase Extension Bolt (1) Install and tighten — Fastener Specifications

  16. Turbocharger Oil Feed Pipe Gasket (3) » Install NEW

  17. Turbocharger Oil Feed Pipe (2) » Install

  18. Turbocharger Oil Feed Pipe Bolt (1) » Install and tighten [2x] — Fastener Specifications

  19. Install the starter (1) through the wheel well.

  20. Electrical Connector (1) » Connect

  21. Install the protective sleeve (2).

  22. Starter Bolt (1) » Install and tighten [3x] — Fastener Specifications

  23. Starter Heat Shield (1) » Install

  1. Starter Heat Shield Bolt (1) » Install and tighten — Fastener Specifications

  2. Starter Heat Shield Bolt (2) » [2x] Install and tighten — Fastener Specifications

  3. Chassis Wiring Harness (4) » Install

  4. Install the positive battery cable retainers to the chassis wiring harness front bracket.

  5. Chassis Front Wiring Harness Bracket Bolt - Front (3) » Install and tighten — Fastener Specifications

  6. Chassis Front Wiring Harness Bracket Bolt - Rear (1) » Install and tighten — Fastener Specifications

  7. Chassis Wiring Harness Front Bracket Retainer (2) » Install [2x]

  8. Intake Manifold Resonator (2) » Install

  9. Engage the retainer spring (1).

  10. Turbocharger Bracket Brace (3) » Install

  11. Turbocharger Bracket Nut (2) » Install and tighten [2x] — Fastener Specifications

  12. Turbocharger Bracket Bolt (1) » Install and tighten — Fastener Specifications

  13. Positive Crankcase Ventilation Hose (2) @ Turbocharger » Install

  14. Positive Crankcase Ventilation Hose Clamp (1) » Engage — Hose Clamp Replacement Guidelines - Spring Type

  15. Hose Clamp (1) » Engage — Hose Clamp Replacement Guidelines - Spring Type

  16. Turbocharger Coolant Return Hose (2) @ Turbocharger Coolant Feed Pipe » Install

  17. Turbocharger Coolant Feed Pipe Bolt (3) » Install and tighten — Fastener Specifications

  18. Catalytic Converter Gasket (3) » Install NEW

  19. Catalytic Converter Clamp (2) » Install NEW

  20. Nitrogen Oxides Catalytic Converter (1) » Install

  21. Install hoses and wiring harness as needed.

  22. Catalytic Converter Brace Bracket Nut (1) » Tighten [2x] — Fastener Specifications

  23. Fuel Cooler Coolant Cooler Inlet Hose » Install

  24. Fuel Heater Inlet and Outlet Nut (1) » Install and tighten — Fastener Specifications

  25. Catalytic Converter Brace Bracket Nut (1) » Tighten [2x] — Fastener Specifications

  26. Catalytic Converter Brace Bracket Nut (1) » Install and tighten [2x] — Fastener Specifications

  27. Install the exhaust gas recirculation cooler (1).

  28. Exhaust Gas Recirculation Cooler Nut (1) » Install and tighten [4x] — Fastener Specifications

  29. Connect the electrical connector at exhaust gas recirculation cooler.

  30. Exhaust Gas Recirculation Cooler Inlet Pipe Gasket (3) » Install NEW [2x]

  31. Exhaust Gas Recirculation Pipe (2) » Install

  32. Exhaust Gas Recirculation Cooler Inlet Pipe Bolt (1) » Install and tighten [4x] — Fastener Specifications

  33. Exhaust Gas Recirculation Valve Cooler Gasket (2) » Install NEW

  34. Install the exhaust gas recirculation valve (1) with the exhaust gas recirculation valve hose.

  35. Exhaust Gas Recirculation Pipe Bolt (1) » Install and tighten [2x] — Fastener Specifications

  36. Exhaust Gas Recirculation Pipe Bolt (2) » Install and tighten [2x] — Fastener Specifications

  37. Connect the electrical connector (1).

  38. Heater Inlet Hose Bracket (2) » Install

  39. Exhaust Gas Recirculation Valve Bracket Nut (1) » Install and tighten — Fastener Specifications

  40. Exhaust Gas Recirculation Outlet Pipe Gasket (2) » Install NEW

  41. Exhaust Gas Recirculation Pipe (1) » Install

  42. Exhaust Gas Recirculation Pipe Nut (1) » Install and tighten — Fastener Specifications

  43. Exhaust Gas Recirculation Pipe Nut (1) » Install and tighten — Fastener Specifications

  44. Position the exhaust pressure differential sensor bracket (2) into place.

  45. Exhaust Pressure Differential Sensor Bracket Stud (1) » Install and tighten [2x] — Fastener Specifications

  46. Install the rear engine wiring harness channel (2).

  47. Install the 3 rear engine wiring harness channel nuts (1). Fastener Specifications

Exhaust Manifold Replacement — figure 92
Exhaust Manifold Replacement — figure 92

  1. Exhaust Pressure Differential Sensor (1) » Install

  2. Install the exhaust pressure differential sensor (2) to the exhaust gas recirculation cooler by engaging the hose clamp (1). Hose Clamp Replacement Guidelines - Spring Type

  3. Install the exhaust pressure differential sensor to the exhaust gas recirculation valve hose by engaging the hose clamp (1). Hose Clamp Replacement Guidelines - Spring Type

Exhaust Manifold Replacement — figure 93
Exhaust Manifold Replacement — figure 93

  1. Exhaust Pressure Differential Sensor (1) » Install

  2. Exhaust Pressure Sensor Hose Clamp (1) » Engage [2x] — Hose Clamp Replacement Guidelines - Spring Type

  3. Exhaust Gas Recirculation Cooler Inlet Pipe (1) » Install

  4. Exhaust Gas Recirculation Pipe Bracket Bolt (1) » Install and tighten [2x] — Fastener Specifications

  5. Turbocharger Coolant Feed and Return Pipe (4) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Install

  6. Exhaust Gas Recirculation Valve Cooling Return Hose (3) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Install

  7. Hose Clamp (1) » Engage [2x] — Hose Clamp Replacement Guidelines - Spring Type

  8. Thermostat Bypass Hose (2) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Install

  9. Hose Clamp (1) » Engage — Hose Clamp Replacement Guidelines - Spring Type

  10. Exhaust Gas Recirculation Cooler Inlet Pipe (5) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Install

  11. Exhaust Gas Recirculation Cooler Outlet Pipe (4) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Install

  12. Heater Inlet Hose (3) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Install

  13. Exhaust Gas Recirculation Coolant Return Pipe (2) @ Exhaust Gas Recirculation Cooler Inlet Pipe » Install

  14. Hose Clamp (1) » Engage [4x] — Hose Clamp Replacement Guidelines - Spring Type

  15. Exhaust Gas Recirculation Valve Inlet Gasket (2) » Install NEW

  16. Exhaust Back Pressure Valve (1) » Install

  17. Catalytic Converter Nut (1) » Install and tighten [3x] — Fastener Specifications

  18. Turbocharger Coolant Feed and Return Pipe Gasket (3) » Install NEW

  19. Exhaust Gas Recirculation Valve Cooling Return Pipe (2) » Install

  20. Exhaust Gas Recirculation Valve Cooling Return Pipe Bolt (1) » Install and tighten [2x] — Fastener Specifications

  21. Exhaust System Front Gasket (2) » Install NEW

  22. Nitrogen Oxides Catalytic Converter (1) » Install

  23. Exhaust Front Pipe Nut (1) » Install and tighten [2x] — Fastener Specifications

  24. Catalytic Converter Brace Bracket (3) » Install

  25. Catalytic Converter Brace Bracket Nut (1) » Install and tighten [2x] — Fastener Specifications

  26. Wiring Harness Retainer (2) @ Catalytic Converter Brace Bracket (3) » Install

  27. Exhaust Front Pipe Nut (1) » Install and tighten [2x] — Fastener Specifications

  28. Exhaust Pipe Clamp (1) » Tighten — Fastener Specifications

  29. Coat the threads of the exhaust particulate sensor (1) with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers

  1. Exhaust Particulate Sensor (1) » Install and tighten — Fastener Specifications

  2. Coat the threads with of the nitrogen oxides sensor – position 3 (1) with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers

  3. Nitrogen Oxides Sensor - Position 3 (1) » Install and tighten — Fastener Specifications

  4. Coat the threads with of the nitrogen oxides sensor – position 2 (1) with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers

  5. Nitrogen Oxides Sensor - Position 2 (1) » Install and tighten — Fastener Specifications

  6. Exhaust Gas Temperature Sensor(1) » Install and tighten — Fastener Specifications

  7. Front Wheelhouse Liner - Right Side (3) » Install — Front Wheelhouse Liner Replacement

  8. Exhaust System Front Gasket (3) » Install NEW

  9. Reductant Fluid Injector (2) » Install

  10. Emission Reduction Fluid Injector Clamp (1) » Install NEW — Fastener Specifications

  11. Exhaust Temperature Sensor - Position 2 (1) » Install — Fastener Specifications

  12. Exhaust Temperature Sensor - Position 1 (1) » Install — Fastener Specifications

  13. Coat the threads of the nitrogen oxides sensor (2) with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers

  14. Nitrogen Oxides Sensor (2) » Install and tighten — Fastener Specifications

  15. Catalytic Converter Clamp (1) » Tighten — Fastener Specifications

  16. Turbocharger Heat Shield (1) » Install

  17. Turbocharger Heat Shield Nut (2) » Install and tighten — Fastener Specifications

  18. Turbocharger Heat Shield Bolt (1) » Install and tighten [2x] — Fastener Specifications

  19. Exhaust Gas Recirculation Cooler Temperature Sensor (2) » Install and tighten — Fastener Specifications

  20. Battery Tray (1) » Install

  21. Engage all wire harness retainers to the battery tray.

  22. Battery Tray Bolt (1) » Install and tighten [7x] — Fastener Specifications

  1. Air Conditioning Evaporator Thermal Expansion Valve Seal - Small (4) » Install NEW
  2. Air Conditioning Evaporator Thermal Expansion Valve Seal - Large (3) » Install NEW
  3. Air Conditioning Refrigerant Heat Exchanger (2) » Install
  4. Air Conditioning Evaporator Thermal Expansion Valve Hose Nut (1) » Install and tighten — Fastener Specifications
Exhaust Manifold Replacement — figure 94
Exhaust Manifold Replacement — figure 94
  1. Air Conditioning Refrigerant Heat Exchanger Nut (1) @ Battery Tray » Install and tighten — Fastener Specifications
Exhaust Manifold Replacement — figure 95
Exhaust Manifold Replacement — figure 95

  1. Air Conditioning Compressor and Condenser Hose Seal - Small (5) » Install NEW

  2. Air Conditioning Condenser and Evaporator Hose (1) » Install

  3. Air Conditioning Condenser and Evaporator Hose Clip (6) » Install

  4. Air Conditioning Compressor and Condenser Hose Seal - Large (4) » Install NEW

  5. Air Conditioning Compressor and Condenser Hose (3) @ Air Conditioning Refrigerant Heat Exchanger » Install

  6. Air Conditioning Compressor and Condenser Hose Nut (2) @ Air Conditioning Refrigerant Heat Exchanger » Install and tighten — Fastener Specifications

  7. Engine Wiring Harness Fuse Block Bracket (3) » Install

  8. Retaining Tab (1) » Engage

  9. Engine Wiring Harness Fuse Block Bracket Bolt (2) » Install and tighten [2x] — Fastener Specifications

  10. Electrical Connector (1) » Install [4x]

  11. Engine Wiring Harness Junction Block (3) » Install

  12. Retaining Tab (1) » Engage [4x]

  13. Engine Wiring Harness Junction Block Bolt (2) » Tighten [4x] — Fastener Specifications

  14. Starter Solenoid Cable (4) » Install

  15. Battery Positive Cable Nut (3) » Install and tighten — Fastener Specifications

  16. Engine Wiring Harness Junction Block Cover (2) » Install

  17. Retaining Tab (1) » Engage [2x]

  18. Battery (1) » Install

  19. Battery Hold Down Retainer (2) » Install

  20. Battery Hold Down Retainer Bolt (1) » Install and tighten — Fastener Specifications

  21. Battery Distribution Engine Compartment Fuse Block (2) » Install

  22. Retaining Tab (1) » Engage [3x]

  23. Battery Positive Post Clamp Nut (1) » Tighten — Fastener Specifications

  24. Electrical Connector (1) » Connect

  25. Front Compartment Fuse Block Cover (2) » Install

  26. Retaining Tab (1) » Engage [2x]

  27. Battery Hold Down Strap (2) » Install

  28. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 159.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 159.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 159.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 159.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

  29. Battery Hold Down Strap Bolt (1) » Install and tighten [2x] — Fastener Specifications

  30. Air Cleaner Outlet Duct (2) » Install

  31. Air Cleaner Outlet Duct Clamp (1) » Tighten — Fastener Specifications

  32. Air Cleaner Outlet Front Duct (2) » Install

  33. Air Cleaner Outlet Duct Clamp (1) » Tighten [2x] — Fastener Specifications

  34. Oil Filler Cap » Remove

  35. Intake Manifold Cover (2) » Install

  36. Intake Manifold Cover Bolt (1) » Install and tighten — Fastener Specifications

  37. Oil Filler Cap » Install

  38. Plenum Front Panel Outer Reinforcement (1) » Install — Plenum Front Panel Outer Reinforcement Removal and Installation

  39. Fill the cooling system to the proper level. Cooling System Draining and Filling

  40. Recharge the refrigerant. Refrigerant Recovery and Recharging

  41. Inspect the exhaust system for leaks.