To Remove:
- Disconnect the negative battery cable.
- Drain the cooling system.
- Disconnect the coolant bypass hose.
- Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
- On vehicles with manual transmission ONLY: Remove the shifter.
- Remove the rear driveshaft.
- Remove the bolts retaining the exhaust inlet crossover pipe to the muffler. Throw away the exhaust converter outlet gasket.
- Remove the bolts retaining the exhaust inlet crossover pipe to the exhaust manifold and remove the right-hand exhaust pipe.
- Keep the transmission supported with a jack.
- Disconnect the transmission electrical connector from the crossmember.
- Remove the 6 bolts retaining the crossmember to the frame.
- Remove the retaining nuts and the crossmember.
- To create access to the EGR valve, lower the transmission.
- Disconnect the EGR coolant hose.
- Remove the bolts and the EGR valve, then throw away the gasket.
- Clean the gasket mating surfaces before installing new gaskets.
To Install:
NOTE: Before installing new gaskets, clean the gasket mating surfaces.
- Install new gaskets.
- Install the EGR valve and bolts.
- Torque to 18 ft-lb (25 Nm).
- Connect the EGR coolant hose.
- Install the crossmember and retaining nuts.
- Torque to 73 ft-lb (99 Nm).
- Connect the transmission electrical connector to the crossmember.
- Keep the transmission supported with a jack.
- Install the right-hand exhaust pipe and the bolts that retain the exhaust inlet crossover pipe to the exhaust manifold.
- Install an exhaust converter outlet gasket, then install the bolts that retain the exhaust inlet crossover pipe to the muffler.
- Torque to 30 ft-lb (40 Nm).
- Install the rear driveshaft.
- On vehicles with manual transmission ONLY: Install the shifter.
- Connect the exhaust gas recirculation (EGR) valve electrical connector.
- Connect the coolant bypass hose.
- Fill the cooling system.
- Connect the negative battery cable.
